Case Study: Electromagnetic Pumps Keep Auto Manufacturer’s Casting Scrap Rate Under 4%
Learn how CMI Novacast has helped a major automotive manufacturer keep its casting scrap rates in the low single digits and consistently achieve its yield targets for over 30 years.
For decades, a well-known automotive manufacturer used iron and gravity pour casting to produce one of its critical, precision parts. The metal and process left much to be desired: the parts were heavy, scrap rates were high, and the relative imprecision of the method resulted in suboptimal yield rates.
In the early 1990s, the manufacturer decided to pivot – and adopt a more modern approach. They settled on using aluminum to lightweight the part, and the rollover process to significantly reduce scrap and increase yield. The rollover process – which was first developed to cast engines for the automotive racing industry – relies on an electromagnetic (EM) pump to move molten metal.
When it came to sourcing EM pumps, the manufacturer knew who to call: CMI Novacast. Having previously used one of CMI Novacast’s EM pumps for research purposes, the manufacturer knew the pump’s superior construction and reliability would allow them to maximize the great potential of the rollover process.
EM Pumps Reduce Scrap, Maximize Yield
CMI Novacast first installed a PG 450 pump for the manufacturer in the 90s – and it exceeded expectations. Because EM pumps use electromagnetism to move molten metal (not moving parts) they reduce the potential for turbulent flow, improve the overall quality and finish of metal, and, by doing so, maximize yield.
After the great success of the first implementation, the manufacturer added PG 450 pumps to several additional production lines. Over the years, the scrap rate associated with the pumps (discoverable during x-ray inspection) has consistently remained under 1% – well below the manufacturer’s already aggressive casting scrap level target of 4%.
Learn How to Modernize Your Automotive Casting Process
CMI Novacast and the manufacturer have enjoyed a three-decades long relationship – which continues to this day. CMI Novacast has successfully completed 11 implementations across four of the manufacturer’s factories. PG 450 pumps are used in six of the manufacturer’s production lines. To date, CMI Novacast pumps have cast nearly 6 billion pounds of metal for the manufacturer.
To learn more about how electromagnetic pumps have allowed the manufacturer to maintain consistently low scrap rates, download the case study. For more information about how EM pumps can accelerate production at your factory or foundry, contact a CMI Novacast factory expert.
