For all designs with conical feeders, the hot spot was located 10 mm above the one in the original design, and the solidification results showed no differences (Figure 4). The experts examined prototypes of all products and found: The conical feeder sleeve does not affect the quality. With the updated design, the cast parts were flawless (Figure 5, exemplary).
Hydraulic power steering covers were previously produced by Fundimig with a casting yield of 59.91 %. And what was the effect of the conical feeder sleeve? The hot spot is located higher up in the feeder with the new sleeve. The casting did not show any changes. Yield increased by 3.19 percentage points with the conical feeder. This means that, for 30,000 castings, Fundimig saved almost 8.5 tons of metal per year. For joint casings, Fundimig increased the yield of the casting processes from 68.36 % to 70.44 %, and thus saved 0.93 kg of metal per finished casting, amounting to approximately 12.2 tons of metal for an annual production of 13,200 parts. In the production of wheel hubs, Fundimig increased the yield on average by 3.5 percentage points to up to 77 %. With a total yearly production volume of all relevant wheel hubs of 11,000 castings, Fundimig reduced the required metal by almost 35 tons.