Commercial Vehicle Foundry

Goal

Transforming Green Sand Performance in a High-Volume Commercial Vehicle Foundry

Outcome

• Sand fusion reduced by ~90%, with scabbing and sand drop defects nearly eliminated.
• Scab rejection reduced by 71%.
• Sand inclusion reduced by 82%.
• Additive cost per MT reduced by 13%.
• Casting rework reduced by 18%.

Net result: improved sand peel-off, collapsibility, and surface finish — leading to lower rework and enhanced overall casting quality.