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NovaCast Technologies AB :
NovaCast’s new Graphyte® 350 material is as easy in machining as gray iron – creates new market possibilities


NovaCast Technologies AB :
In a cooperation project with Sandvik Coromant NovaCast has conducted extensive tests and evaluations of CGI material produced according to the newly launched Graphyte® technology from NovaCast’s subsidiary Graphyte AB. The tests were conducted at Sandvik’s Research Center in Västberga. The evaluation of one of three material qualities is completed and shows surprisingly good results.

According to Sandvik’s test results the CGI quality Graphyte® 350 shows better or at least equally good machining properties as gray iron.

Graphyte® 350 is excellently suited for production of e.g. cylinder heads in CGI. When using Graphyte® 350 considerably better performance can be achieved without increasing machining costs, previously a hinder for introducing CGI into the automotive industry.

The tests included Graphyte® 350, 450 and 500 material qualities. Evaluation of Graphyte® 350 is now completed. Tests have among others included measuring cutting tool longevity in relation to machining speed at a certain energy consumption, as well as tool longevity in relation to machined surface or depth. Results show that the NovaCast Graphyte® 350 material has better or at least equally good machining properties as the reference material, gray iron. Gray iron is currently used in the majority of engine applications. Introducing the considerably more suitable CGI material has been hindered by expense increasing process costs and machining costs.

NovaCast’s patented Graphyte Flow® method can considerably reduce process costs since addition of alloys takes place in the existing production line using an ingenious reaction chamber that also reduces fumes, a recurring problem within the foundry industry.

Formation of carbides in CGI material can be avoided since the metallurgical reaction takes place in a closed chamber. Carbides have a negative impact on machining properties.

The Graphyte® process results show that both process costs and machining costs are comparable to those for gray iron. However, with Graphyte® 350 product strength is higher and engine performance can be increased.

Graphyte® 350 is therefore a very suitable material for the production of cylinder heads. Production of engine blocks, however, requires Graphyte® 450 material or higher. Graphyte® 350 also opens up the possibility of moving from ductile iron, which is difficult in machining, to Graphyte® 350, while retaining all the positive qualities of ductile iron. Products appropriate for Graphyte® 350 that are currently being produced in ductile iron are e.g. exhaust manifolds and bedplates.

Evaluation of remaining Graphyte® qualities will be completed during autumn of 2008.

NovaCast Technologies, listed on the OMX Nordic Exchange (NCAS B), develops and markets enhanced castings for the production of car body parts, as well as software for methoding, simulating and process control for more efficient production processes to the global automotive industry and its subcontractors. With the Camito technology enhanced castings are manufactured in one solid piece for the production of dies for forming and stamping automotive body components in a considerably shorter time than traditional dies. Through die manufacturer SwePart the group has expertise within the whole value chain for the production and sales of stamping dies.

For further information from NovaCast contact Hans Svensson, CEO NovaCast Technologies AB, +46 705 652 250.

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