Proven Performance Over Existing Additives with Lustron

Goal

Reduce Casting Roughness and Additive Consumption Without Disrupting High-Volume Output

The facility produces gearbox housings, differential and transmission cases, axle and rockshaft housings, and other precision components on a KW molding line with modern melting facilities and integrated CNC machining. The goal was to bring casting roughness on critical components under control while lowering bentonite, carbonaceous additive, and overall consumable cost per tonne of liquid metal.

Challenge

• Casting roughness and sand fusion
• Excess consumption of additives
• Insufficient sand collapsibility during shakeout

Outcome

With Lustron specified to VM ≥45.0%, Ash ≤5.0%, and 80% minimum passing at 0.212mm, before-and-after trial data showed consistent improvement across every measured parameter:

• Bentonite consumption reduced from 79.32 to 69.58 kg/MT LM (12.27% improvement)
• LCA (Lustrous Carbon Additive) reduced from 34.07 to 28.62 kg/MT LM (15.99% improvement)
• Total M/R reduced from 5.39% to 3.6% (33.30% improvement)
• Consumables cost reduced from ₹770 to ₹672 per MT (12.72% improvement)
• Casting roughness on critical components reduced from 25–30% to below 5%
• Smoother surface finish, fewer sand-related defects, improved sand collapsibility during shakeout