Foundry full-service provider
MAN Energy Solutions's foundry is one of the oldest workshops in the plant in Augsburg, Germany. It has been in operation since 1844 and offers experience and professional knowledge in the production of high-quality castings.
We are one of the last system providers in the foundry business – specialized, amongst others, in casting very large components with a weight up to 100 tons such as crankcases or cylinder heads. Many years of experience in casting technology, patternmaking and heat treatment are our foundation to advise you in designing components and selecting casting materials. We specialize in the production of castings for: engine blocks, gear drive housings, planet carrier, compressors, turbochargers, and mechanical engineering parts. When it comes to Ductile iron castings, our foundry workshop is known for its high-quality standards. These requirements are permanently checked and verified by our certified quality management system.
Our offer
We offer castings from 300 kg up to 100 tons. For this we use different processes in the molding shop:
- For small sizes we have a semi-automated molding line and one sand mixer. The flask sizes are up to 1600mm x 1600mm with a capacity of 80 flasks a day up to 2.5t per piece.
- For middle sized products we have 4 manual molding stations, each with its own mixer. In this area we can produce components with 40t and up to 8m length.
- For large castings up to 100t raw casting weight, we can provide 13 large molding pits. The maximum dimensions can be 14m x 4.5m x 3m.
Complete foundry process in-house
As a full-service provider we can offer the complete foundry process in-house, from patternmaking to metal melting and iron casting.
1. Patternmaking
Patternmaking is the first and most essential part of the casting process.
Our services include:
- CNC milling machines with five axes
- All quality classes in accordance with EN 12890
- Measuring with portable 3D scanner
- Maintenance and repair of smaller damages
- Changes due to data revisions
2. Core shop
High-quality cores are essential to the iron casting process – from blasting to the conventional cold resin process.
- In the foundry workshop we produce 75,000 cores per year – core weight of about 100g up to 10 tons
- Water and alcohol-based coatings are used
- Five core blasting machines up to 300 liter volume - 10/15 liter; 20/40 liter; 30/50 liter; 300 liter
- These machines are used for producing complex core structures or series cores.
3. Molding shop
We provide in our molding shop a hand mold and semi-automated molding line from 300 kg up to 100 tons. With a component size up to 14 m length and 100 tons.
4. Melting shop
Our melting shop in Augsburg has a capacity of 40,000 tons per year.
We can offer the following services
- 14MW connected load
- Cast iron materials gray iron, ductile iron and SiMo ductile iron
- 2x 6to medium (MF) and 2x 23to frequency (NF) induction furnaces
- Emission spectrometer, thermal analysis, carbon combustion method
6. Rapid prototyping
- Very well practiced process
- Very good connection to subcontractors for core printing.
5. Fettling shop
- Fully-automated fettling station
- Three shot blasting machines
- Annealing furnace up to 900 °C
7. Additional services
- Quality control
- Engineering
- CNC machining shop up to 100t parts
- Paint shop
- Iron cast welding
- Service parts and proven project management
MAN Energy Solutions’ Foundry is your reliable partner for complex metal castings up to 100 tons.
Your benefits:
- Long history with extensive experience, casting know-how and state-of-the-art casting technology
- High quality standards and proven long-term customer satisfaction
- Full system provider with additional services and unique selling points like engineering, prototyping, quick service parts, single lots and excellent project management
- Part of the VW Group