As foundries strive to produce more complex castings with thinner section thickness, the requirements placed upon the moulding media is increased to new levels. Failure within the moulding media, during the casting operation will result in increased levels of re-work and scrap. Within the costing systems of the modern foundry, it is essential to control costs, especially the variable costs, as fluctuations can mean the difference between a profit and loss on a particular job. Both scrap and re-work are significant components of the overall cost, and by maintaining these at minimum levels, they can have a very beneficial effect on the balance sheet. It is for these reasons that investment in processes which minimise scrap and re-work, is essential. The innovations described in this paper, have focused on one such process, a process aimed at improving the as-cast quality of a component, a process which can, with a limited on-cost, significantly reduce the total component cost.
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