American Foundry Society (AFS) MetalCasting Congress
Cleveland, Ohio, 25–27 April 2023
During the annual AFS MetalCasting Congress, Dr Steve Dawson, President & CEO, presented a paper entitled: “Small, In-line Passenger Vehicle Engines: Cast Iron with the Same Weight as Aluminium”. The Ultra-Light cylinder block concept – jointly developed by Tupy, SinterCast and Ricardo – was also presented by Tupy one week earlier at the Society of Automotive Engineers (SAE) World Congress in Detroit on 20 April.
Also at the MetalCasting Congress, Dr Dawson was recognised with the AFS Award of Scientific Merit for his contributions to the development, production and application of Compacted Graphite Iron. He is pictured together with Tom Schroeder, Technical Director and companion, who celebrated his 30th anniversary with SinterCast during the Congress.
World Foundry Congress, Busan, Korea
Dr Steve Dawson, President & CEO, provided a keynote lecture at the World Foundry Congress in Busan Korea on 18 October 2022. The lecture was originally planned to be given by Dr Wilson Guesser, the former Technical Director of Tupy, who sadly passed away in February 2020. Dr Dawson was invited by the World Foundry Organisation to give the lecture in honour of Dr Guesser. The title of the keynote lecture was “Compacted Graphite Iron: Past, Present and Future” – a topic on which Wilson and Steve collaborated for more than 25 years.
Ductile Iron Society
Fall Meeting 2021, Kohler Wisconsin
On the anniversary of his 30th year with SinterCast, Dr Steve Dawson, President & CEO, was invited to present the opening lecture at the Ductile Iron Society Annual meeting on 1 December 2021. Dr Dawson’s presentation, entitled 30 Years in 30 Minutes, addressed observations and advances in the cast iron foundry industry over the past thirty years, and provided reflections on opportunities for further improvements in efficiency and quality in the future.
Foundry on Wheels Conference
15 October 2021, Portugal
SinterCast made two presentations at the Foundry on Wheels conference in Portugal on 15 October 2021. Dr Steve Dawson, President & CEO, made a presentation entitled “The Future of Powertrain: where are the cars and trucks going?” while Arnaud Denis, Chief Engineer – Tracking Technologies, and Luis Fernando Guedes of Tupy Mexico made a joint presentation entitled “Traceability and Industry 4.0 Process Control at Tupy Mexico”.
Russia STCIM Symposium
17-18 November 2020, remote web-format
Dr Steve Dawson, President & CEO, was invited to provide a presentation at the Science and Technology of Cast Iron materials (STCIM) Symposium, 17-18 November 2020. Due to the limitations of 2020, the symposium was held in a remote web-format. The conference was a continuation of the work aimed at uniting and developing the efforts of specialists in developing the properties and application of Cast Iron, started at the inaugural PTCCGI symposium in 2017 and the STCIM symposium in 2018. Dr Dawson’s presentation was entitled “CGI Process Control Requirements”, addressing the requirements for reliable control of the production of Compacted Graphite Iron (CGI) in the foundry, followed by an explanation of how the SinterCast technology can resolve these challenges. The invitation to participate in the Russian STCIM Symposium reinforces both the technical advantages of the SinterCast technology and the position of SinterCast as a welcomed and respected member of the international cast iron research community.
2nd Carl Loper Cast Iron Symposium
30 September – 1 October 2019, Bilbao, Spain
Dr Steve Dawson, President & CEO, was invited to provide a keynote lecture at the 2nd Carl Loper Cast Iron Symposium in Bilbao, Spain, 30 September – 1 October 2019. Held in honour of Professor Loper – and following the first Symposium held in 2009 – the event brings together cast iron researchers from academia and industry. Dr Dawson’s presentation was entitled “Automotive Powertrain Trends and the Market opportunity for Cast Iron”. The invitation to provide a keynote lecture reinforces the position of SinterCast as a respected industrial company and a welcomed member of the cast iron research community.
2019 FENAF Latin American Foundry Fair, São Paulo, 17-20 September
Hosted by the Brazilian Foundry Association (ABIFA)
Dr Steve Dawson, President & CEO, provided the opening keynote lecture at the 2019 Latin American Foundry Fair, held in São Paulo, Brazil, 17-20 September 2019. Entitled “Industry 4.0 Process Control and Traceability in the Cast Iron Foundry Industry”, the lecture focussed on the application and benefits of the SinterCast Ladle Tracker® and the SinterCast Cast Tracker® technologies. The presentation began with an overview of market trends for passenger vehicle and commercial vehicle powertrains and concluded with life cycle energy analyses for cast iron vs. aluminium cylinder blocks and for internal combustion engines vs. electric vehicles. Together, these topics served to motivate the positive long-term future for the cast iron foundry industry, and to define the need for improved process control and traceability to meet the increasingly stringent quality demands of the automotive industry.
GIFA World Foundry Trade Fair, 25-29 June 2019
The GIFA world foundry trade fair, held every four years in Düsseldorf, is the world’s most important event for metallurgy and casting technology. It provided the opportunity for SinterCast to display its industry leading Compacted Graphite Iron (CGI) process control technology and to promote the benefits of CGI. Since the last GIFA in 2015, SinterCast series production has grown by 45% and the number of installations has increased by 30%. At GIFA 2019, SinterCast launched the System 4000, the company’s fourth generation process control technology for the reliable series production of CGI. SinterCast also took the opportunity to present its new Tracking Technologies – SinterCast Ladle Tracker® and SinterCast Cast Tracker® – for traceability and process optimisation in ferrous and non-ferrous foundries, and in other metallurgical facilities. The suite of SinterCast technologies displayed at GIFA 2019 provides solutions for high volume, niche volume and rapid prototype production of CGI, and for Industry 4.0 traceability of the liquid metal, the core packages, the moulds, and of every individual casting.
Jönköping University - School of Engineering, 17 May 2019
Dr Steve Dawson, President & CEO, was invited by the Jönköping University School of Engineering to provide a lecture at the 6th Cast Iron Course – a one-week PhD-level lecture series. The lecture series focusses on the metallurgy, solidification and modelling of cast iron castings and is widely regarded by the cast iron community as the foremost education forum for university and industry researchers. Together with lecturers from Argentina, France, Sweden and the United States who provided presentations on the fundamentals of cast iron, Dr Dawson provided a lecture entitled Development Trends for Automotive Powertrains and the Future of Cast Iron.
North American International Auto Show - Detroit, January 2019
The 2019 North American International Auto Show (NAIAS) provided the venue for the launch of the all-new 6.7 litre in-line diesel engine for the Ram Super Duty pick-up, based on a SinterCast-CGI cylinder block. The start of production of the Ram diesel marked the first application of CGI for in-line diesels in a passenger vehicle application, and provided high volume series production references in each of the Five Waves that SinterCast first presented in 2002. The NAIAS also saw the Ford F-150 pick-up win a coveted Wards 10 Best Engine award for the SinterCast-CGI 3.0 litre V6 diesel engine. The award marked the fifth consecutive year that a SinterCast-CGI engine has received a Wards 10 Best Engine award. A selection of SinterCast-CGI vehicles at the NAIAS is shown below, together with the available SinterCast engine options.
Ford F-150: 2.7L V6 Petrol & 3.0L V6 Diesel
Ford Super Duty: 6.7L V8 Diesel
Ford Explorer: 3.0L V6 Petrol
Lincoln Aviator (3.0L), Continental (3.0L), MKZ (3.0L) & Nautilus (2.7L)
Nissan Titan: 5.0L V8 Diesel
Ram 1500: 3.0L V6 Diesel
Ram Super Duty: 6.7L In-line Diesel
Ductile Iron Society, 6th Keith Millis Symposium - Hilton Head, USA, 23-26 October 2018
Dr Steve Dawson, President & CEO, was invited by the Ductile Iron Society to deliver the keynote address at the 6th Keith Millis Symposium, 23-26 October 2018. Held every five years to commemorate the first observations of ductile iron, the Millis Symposium is one of the most important international events for the cast iron industry, including foundries, suppliers and researchers. Dr Dawson’s keynote presentation, entitled: “Cast Iron: we Just Need to Get Better at Telling our Story” provided an overview of the early development of Compacted Graphite Iron, followed by a discussion on the importance of life cycle analyses to truly understand the benefits and costs associated with the use of aluminium for weight reduction, and with the use of electric vehicles instead of internal combustion engines. Dr Dawson concluded that it is important for legislators to look beyond tailpipe emissions to determine which technologies are truly best for society.
Russian Conference on the Science and Technology of Cast Irons - Naberezhnye Chelny, Russia, 15-19 October 2018
The second annual Russian Conference on the Science and Technology of Cast Irons was held in Naberezhnye Chelny, 15-19 October 2018. During the conference, Dr Steve Dawson, President & CEO, gave an invited presentation entitled “Thermal Analysis of Crystallisation of Cast Iron”. In conjunction with the conference, SinterCast conducted a CGI casting demonstration at the KAMAZ Commercial Vehicle foundry in the host city of Naberezhnye Chelny. The trial was an invitation-only event attended by approximately 20 of the delegates, and marked the first casting of SinterCast-CGI in Russia. Together, the presentation and the demonstration served to reinforce the technical advantages of the SinterCast technology and to broaden the confidence in the SinterCast process control technology within the Russian foundry and academic communities.
World Foundry Congress - 24 September 2018, Krakow
At the 73rd World Foundry Congress on 24 September 2018 in Krakow, Poland, Mr. David Gilson, Sales and Marketing Director, presented “Industry 4.0 Process Control and Traceability for the Foundry Industry”. The World Foundry Congress is the annual technical conference convened by the World Foundry Organisation, composed of national foundry industry groups throughout the world. The presentation explained how the SinterCast Ladle Tracker® and SinterCast Cast Tracker® technologies enable foundries to trace castings from coremaking through to shipping, and to link each casting to the ladle from which it was poured. Following the presentation, several OEMs discussed how their foundry supply base can adopt the technologies for improved process control and traceability.
AISTech 2018, May 2018
At the recent Association for Iron and Steel Technology (AISTech) conference on 7 May 2018 in Philadelphia, Mr. David Gilson, Sales and Marketing Director, presented “Ladle Tracking Technology for Improved Process Control.” AISTech is the primary North American technical conference for the steel industry. Attendees included global steel producers, global equipment and technology suppliers, and university researchers.The event marked the first public presentation on the SinterCast Ladle Tracker® technology for steel mills. The presentation was followed by a question and answer period where various steel industry personnel discussed opportunities where the Ladle Tracker technology would be beneficial for automated tracking in the melting and casting production areas.
American Foundry Society 2018 - Metalcasting Congress, 3-5 April 2018, USA
Tom Schroeder, Technical Director, was presented with the AFS Engineering Division's best presentation award. The Special Merit Award was given for Mr Schroeder's presentation at the 2017 AFS Congress entitled: “A Novel Approach to Process Control and Traceability in the Cast Iron Foundry Industry”. Co-authored with Tupy and Ford, the paper detailed the application and benefits of the SinterCast Ladle Tracker® technology installed at the Tupy foundry in Saltillo, Mexico.
CASTcon 2018 - Cast Metals Federation, UK, 27-28 March 2018
Dr Steve Dawson, President & CEO, presented the SinterCast Tracking Technologies at the UK Casting Conference at Cranfield University, 27-28 March 2018. Attended by approximately 200 foundry engineers, managers and researchers, the presentation provided the opportunity to update the UK foundry industry on the progress that has been made with the SinterCast Ladle Tracker®, SinterCast Cast Tracker® and Operator Tracker™ technologies.
Indian Foundry Congress, January 2018
At the 66th Indian Foundry Congress (IFC) in Gandhinagar, India, Mr. David Gilson, Sales and Marketing Director, presented a technical paper titled “Process Control for the Reliable High Volume Production of Compacted Graphite Iron”. The technical paper was published in the IFC conference proceedings. The IFC is the primary foundry conference held in India on an annual basis. Attendees included global equipment and technology suppliers, foundrymen and OEMs from India and the Middle East, and Indian university researchers. The presentation was followed up with discussions with prominent Indian OEMs on the use of Compacted Graphite Iron for commercial vehicle, construction, and industrial power engine applications.
North American International Auto Show, Detroit, January 2018
The Ford F-150 pick-up, America’s best-selling truck for 41 consecutive years and the 2018 Motor Trend Truck of the Year, became the first full size pick-up to offer 30 mpg fuel economy (7.8 litres / 100 km) with the new SinterCast-CGI 3.0 litre V6 turbo diesel. Also in the Ford F-150, the SinterCast-CGI 2.7 litre V6 petrol engine won a coveted Wards 10 Best Engines award – the only pick-up engine to receive a Wards 10 Best award in 2018.
Scroll down to see some of the SinterCast-CGI vehicles on display.
Tupy Investor Open House - 8 and 11 December 2017
Dr Steve Dawson, President & CEO, was invited as the guest speaker at 'Tupy Day 2017', on 8 December 2017 in Joinville, Brazil. An annual open house for investors, Tupy Day 2017 attracted more than 40 analysts and investors. Dr Dawson presented the benefits of CGI, a comparison of CGI and aluminium, a powertrain outlook for 2020 to 2030, and an overview of life cycle emissions from internal combustion engines and electric vehicles. On Monday, 11 December, Dr Dawson accompanied the Tupy executive management to participate in an international web-based investor briefing hosted by the UBS offices in São Paulo, London, New York and Boston.
Foundry on Wheels Conference - CITNM, Portugal 19-20 October 2017
Professor Robert Dover, SinterCast Board member, provided the keynote address at the CITNM Foundry on Wheels conference in Águeda, Portugal. Professor Dover presented the SinterCast perspectives on the future of the powertrain and the future of the automotive foundry business. Read the interview given by Professor Dover following his keynote address.
Russian CGI Conference - Naberezhnye Chelny, Russia, 17-19 October 2017
The first annual Russian CGI Conference was held in the home city of KAMAZ, Russia’s largest truck and off-road equipment manufacturer, 17-19 October 2017. During the conference, Dr Steve Dawson, President & CEO, gave three presentations to discuss: (i) the fundamentals of graphite growth in CGI; (ii) the process control requirements for CGI; (iii) and the use of the SinterCast technology for reliable high-volume series production of CGI. Attended by approximately 100 delegates from the Russian foundry industry, the supply industry, university researchers, and the Russian car and truck OEMs, the conference provided the opportunity to introduce the SinterCast process control technology and production experience to the Russian CGI community.
German Foundry Association (VDG, BDG) - Cupola Conference, Saarbrücken, Germany, 22-23 June 2017
Dr Steve Dawson, President & CEO, presented the SinterCast tracking technologies at the German Foundry Association’s Cupola Conference in Saarbrücken, Germany, 22-23 June 2017. Attended by 220 foundry engineers and managers from Europe, Asia and the Americas, the conference provided the opportunity to introduce a wide audience to the SinterCast Ladle Tracker®, SinterCast Cast Tracker® and Operator Tracker™ concepts.
American Foundry Society (AFS) - Annual Metalcasting Congress, 25-27 April 2017
At the American Foundry Society annual conference, Mr. Tom Schroeder, Technical Director, presented the use of the SinterCast Ladle Tracker™ technology at the Tupy foundry in Saltillo, Mexico. The paper was co-authored by Tupy and Ford. Beyond the core Ladle Tracker™ technology, the presentation introduced the ability of the SinterCast technology to track other aspects of the foundry process, including moulds, castings and even the performance of individual operators. Also at the AFS Congress, Mr. David Gilson, Sales and Marketing Director, participated in a panel discussion on the effect and control of grey iron skin in ductile iron and CGI castings. The panel included speakers from SinterCast, Caterpillar, American Castings, and the University of Alabama-Birmingham.
Shanghai International Automobile Exhibition, April 2017
JMC has unveiled a new heavy duty commercial vehicle for the domestic Chinese market. The two engine options available are based on SinterCast-CGI. Both the cylinder block and head in the 9.0 litre engine and the cylinder head in the 13.0 litre engine are produced using the SinterCast process control technology at the ASIMCO International Casting Co., Ltd foundry in Shanxi, China.
North American International Auto Show, Detroit, January 2017
On the opening day of the 2017 North American International Auto Show, Ford announced a 3.0 litre V6 diesel engine option for the Model Year 2018 F-150 pick-up. Based on a SinterCast-CGI cylinder block, the engine will be the first-ever diesel offered in the F-150. Together with the 2.7 litre V6 SinterCast-CGI EcoBoost® petrol engine, the introduction of the diesel engine option results in two of the five engine options in America’s best-selling vehicle being based on SinterCast-CGI cylinder blocks.
GIFA World Foundry Trade Fair, 16-20 June 2015
Held every four years in Düsseldorf and hosting more than 75,000 visitors from 120 countries around the world, GIFA provides the opportunity for SinterCast to display its industry leading Compacted Graphite Iron (CGI) process control technology and to promote the benefits of CGI. The SinterCast technology display presented foundry solutions for all levels of CGI production, including the Mini-System 3000 for prototyping and niche volume production; the System 3000 with SinterCast’s patented feedforward optimisation of magnesium and inoculant prior to casting; and, the fully automated System 3000 Plus that additionally incorporates automatic feedback control of the base treatment process. SinterCast also took the opportunity of the GIFA world foundry trade fair to promote the use of CGI in a variety of components including exhaust manifolds and turbocharger housings, passenger vehicle cylinder blocks and commercial vehicle cylinder blocks and heads, with casting weights ranging from 5 kg to 300 kg. Prominent among the cylinder blocks on display is the world’s first high volume CGI petrol engine cylinder block, the Ford 2.7 litre V6 EcoBoost, establishing a new benchmark for CGI in petrol applications. The display also included a direct comparison between the Audi 3.0 litre V6 CGI cylinder block and the Mercedes 3.0 litre V6 aluminium cylinder block, highlighting that the assembled Compacted Graphite Iron engine is 125 mm shorter and weighs 15 kg less than the aluminium engine.
Yulin City, China, August 2014
SinterCast presented a paper titled "Process Control for High Volume Production of Compacted Graphite Iron in China" at the 9th National Conference on Cast Iron and Melting held in Yulin City, Guangxi Province, China from 7-9 August, 2014. The paper was co-authored by Dr. Steve Dawson of SinterCast AB and Mr. David Gilson of SinterCast Inc. Mr. Gilson and Dr. Jincheng Liu, SinterCast China, presented the paper to over 200 attendees from various companies in the Chinese foundry industry. The conference was organised by the Cast Iron Committee of the Foundry Institution of Chinese Mechanical Engineering Society (FICMES).
North American International Auto Show, Detroit
Jeep Grand Cherokee Limited
Jeep Grand Cherokee Overland
Jeep Grand Cherokee Summit
4th Automotive Weight Reduction Expo, Tokyo, Japan
SinterCast's world-class technology for the production of Compacted Graphite Iron (CGI) was recently on display at the 4th Automotive Weight Reduction Expo held in January of 2013 in Tokyo, Japan. The conference was attended by over 6,000 global industry professionals interested in the latest trends for the weight reduction in automotive applications. SinterCast was represented at the conference through its local friendship with Morimura Bros. Inc., one of Japan´s leading industrial trading houses.
Zibo Conference 2012
SinterCast presented two papers at the 2012 Chinese National Compacted Graphite Iron (CGI) Conference in Zibo City, Shangdong Province, China, 10-13 September, 2012. The first paper and presentation, by Dr. Steve Dawson of SinterCast AB, was entitled "Process Control for the Reliable High Volume Production of Compacted Graphte Iron".
The second paper and presentation, entitled "Standards, Microstructure, Property and Process Control of Compacted Graphite Cast Iron" was presented by Dr. Jincheng Liu of SinterCast China. The conference, organized by the Foundry Institution of Chinese Mechanical Engineering and the Cast Alloy Technical Committee of the Chinese Society of Rare Earths, attracted approximately 120 attendees from various companies in the Chinese foundry industry interested in CGI production.
Prior to the Conference, SinterCast organized a seminar for invited guests to present CGI market updates and information regarding the SinterCast Process Control Technology for CGI production. This seminar attracted over 50 managers and executives from key Chinese cylinder block and head foundries.