SinterCast’s compacted graphite iron (CGI) production has demonstrated unprecedented growth, marking nine consecutive quarters of expansion. In June 2023, monthly production achieved an annualized rate of 4.1 million engine equivalents, translating to 205,000 tonnes of CGI. This milestone underscores the accelerating adoption of CGI by global castings manufacturers seeking lightweight, high-performance solutions. Monthly progression highlights this momentum:
| Month (2023) | Annualized Engine Equivalents | Annualized Tonnage (tonnes) | Monthly Tonnage (tonnes) |
|---|---|---|---|
| April | 3.1 million | 155,000 | 12,916.7 |
| May | 3.9 million | 195,000 | 16,250.0 |
| June | 4.1 million | 205,000 | 17,083.3 |
Each engine equivalent represents 50 kg of CGI, matching a typical passenger vehicle cylinder block weight. Quarterly performance further exemplifies this trajectory:
$$ \text{Q2 2023 Production} = 3.7\ \text{million engine equivalents} = 185,000\ \text{tonnes annualized} $$
From inception in 1999, SinterCast’s journey to key milestones reveals exponential growth:
| Year | Engine Equivalents Milestone | Duration |
|---|---|---|
| 2015 | 2 million | 16 years |
| 2023 | 4 million | 8 years |
Sampling cup shipments—critical for process control—surged 50% in Q2 2023 to 49,500 units, indicating revived supply chains and inventory rebuilding among castings manufacturers. The growth aligns with CGI’s material superiority:
$$ \begin{align*} \text{Tensile Strength}_{\text{CGI}} &> \text{Tensile Strength}_{\text{Gray Iron}} \\ \text{Fatigue Resistance}_{\text{CGI}} &> \text{Fatigue Resistance}_{\text{Aluminum}} \end{align*} $$
These properties drive demand from diesel/gas engine manufacturers for weight reduction, noise suppression, and emission control. For castings manufacturers, metal purity remains paramount. Traditional ceramic foam filters exhibit limitations, generating loose particles during sintering that contaminate molten metal:
EXACTPORE 3D filters overcome this via additive manufacturing, ensuring structural integrity and eliminating particle shedding. Their uniform pore geometry enhances flow dynamics versus traditional filters:
$$ \text{Flow Rate}_{\text{EXACTPORE 3D}} = k \cdot \frac{\Delta P \cdot d_p^2}{\mu \cdot L} $$
where \(d_p\) = pore diameter, \(\Delta P\) = pressure drop, \(\mu\) = viscosity, \(L\) = filter thickness, and \(k\) = geometric efficiency constant. This design minimizes turbulence, curbing reoxidation and inclusions. Benefits include:
| Parameter | EXACTPORE 3D Impact |
|---|---|
| Scrap Rate | ↓ 15-25% |
| Surface Quality | ↑ 30-40% |
| Production Efficiency | ↑ 20% via higher flow rates |
Bob Gage, North American EVP, emphasizes: “Additive manufacturing enables limitless pore design customization. We guarantee optimal filtration quality for castings manufacturers, even for unconventional specifications.” As SinterCast targets 5 million engine equivalents, integrated technologies like EXACTPORE 3D will empower castings manufacturers to scale CGI applications while enhancing quality and profitability.