Gravity Casting Plant

Gravity Casting Plant
In this area we produce cylinder heads, i.e. the parts of combustion engine which close the working area of the cylinders from the top, and connected with the engine block. Every fourth car manufactured by VW AG is equipped with a cylinder head from Poznań.
The technology of production of cylinder heads consists of the following stages:

Melting Shop
At this stage, so called ingots (aluminium blocks) and scrap from internal stages of production, such as machining, are melted. The furnaces used here are gas fuelled (shaft furnaces) with total capacity of up to 10 t/h, and auxiliary induction furnaces.

Core Production Shop
The plant manufactures sand cores both in Cold-Box and Hot-Box technologies. At present we also perform tests in the production of unlimited technology, which apart from its multiple technical advantages is environment friendly.
While the sand cores are indispensable for shaping the internal spaces of the cylinder head, its external contour is ensured by the mould. After casting and cooling the cylinder head, the cores are removed in the process of shaking. The cores manufactured using the Cold-Box method require special technology of shaking, in which after the stage of typical hammering the cylinder head is put into simultaneous vibration and rotation, thus enabling the sand to get out of each channel and space of the cylinder head.

Casting Plant
In 2008 we started the world most advanced technology in terms of casting process automation. Six rotary tables, each of which being able to cast one cylinder head every minute, are foreseen for the production of cylinder heads for the new engines, such as 2.0 CR, 2.0 TFSI or 1.2 TSI.

Machining
In the case of cylinder heads, the machining is carried out on 6 machining lines up to the stage of initial treatment. This processing stage includes: cutting of the riser heads, drilling and milling.

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Gravity Casting Plant