Dongfeng Commercial Vehicle
Technical Center
Compacted Graphite Iron
22 March 2017
©SinterCast
SinterCast and the Market
SinterCast is
• SinterCast is a Swedish Company
– First patent 1983
– Publicly traded on Stockholm Stock Exchange since 1993
– 7.1 million shares and approximately 3,600 shareholders
– Market Cap: ~EUR 65 million
– 8 patents filed or granted in 58 national phase applications
©SinterCast
SinterCast Experience and Service
Production Experience and Technical Support
• Current Production Rate:
– Current Annualised Production: 110,000 tonnes shipped castings
– Number of Castings Produced: >2 million
– Number of ladles controlled: >150,000 (~300,000 tonnes liquid iron)
• Current Production Support:
– >60 CGI components in series production
– 100,000 cylinder blocks per month
– 2.7 kg to 9,000 kg per piece
– 21 different installations
– 11 countries and 10 languages
• Total Installations (44)
– 24 System 3000 and System 3000 Plus
– 20 Mini-System 3000
– 13 countries and 10 languages
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Global Installations
Tupy Saltillo,Mexico (Cifunsa) 1996 Daedong, Korea 2011
VDP, Italy 1998 Daeshin, Korea 2011
Halberg Guss, Germany 1998 Toa Koki, Japan 2011
Caterpillar, USA 1999 Wuxi Diesel (FAW), China 2011
Tupy, Joinville, Brazil 2000 Mid-City, USA 2011
SKF, Sweden 2000 YTO, China 2012
Federal Mogul, Sweden 2001 Undisclosed, Japan 2012
Teksid, Global (Mexico) 2002
Tupy Saltillo, Mexico 2012
Fagor Tafalla, Spain 2003
Scania, Sweden 2013
Motor Castings, USA 2004 UAB, Birmingham, USA 2013
G & W, England 2004 Halberg Guss, Germany 2013
Tupy, Mauá, Brazil 2004 Jiangling Motors Co., China 2013
Hyundai, Jeonju, Korea 2005 Tupy, Joinville, Brazil-Foundry C 2013
Componenta, Turkey 2005 Zhongding Power, China 2014
Ashland, USA 2005 Impro Industries, China 2014
Dashiang Precision, China (2) 2005 Dongfeng Trucks, China 2015
Ford, USA 2006
Doosan, Korea 2015
Doosan, Korea 2006
Volvo, Sweden 2007 Undisclosed, Japan 2015
Case, USA 2007 ASIMCO, China 2015
Luitpoldhütte, Germany 2009 Teksid, Portugal 2015
FAW, China 2010 Teksid, Brazil 2015
44 Total Installations, 13 Countries, 10 Languages
©SinterCast
Series Production
Series Production References
• High volume series production in passenger vehicle sector
– 75,000 SinterCast-CGI cylinder blocks per month
– Cummins, FCA, Ford, Hyundai-Kia, VW-Audi
– SinterCast-CGI engines available in 52 vehicles and 18 car brands
– Exhaust components: BMW, Renault, VW, Honeywell, BorgWarner
– Clutch components: Ford, Aston Martin
• Commercial vehicle engine components
– 21 SinterCast-CGI components in series production
• Continuous production in the Industrial Power sector
– CAT, Cummins, Deutz, Federal Mogul, GE, Liebherr, MAN, MTU
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Passenger Vehicles
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Series Production
Audi 3.0 Litre V6
• Production start: 2003/04
• Gen 2 Upgrade 2010
– 6.5 kg block weight reduction
– 25 kg engine weight reduction
• Total volume: 250,000 per year
• Tupy Joinville
• 200, 235 and 246 horsepower
– 50~61 kW/l
• 550 Nm from 1,250-3,500 rpm
• Audi Porsche & VW vehicles
• Euro VI compliant
©SinterCast
Series Production
Cummins 5.0L V8
• Production start: 2014
• Mature volume: 100,000 per year
• Tupy Joinville
• 310 horsepower (231 kW)
• 750 Nm from 1,250-3,500 rpm
• Nissan Titan XD pick-up
• Cummins ISV5.0 engine variants
from 200-275 horsepower
• US EPA 2015 compliant
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Series Production
Ford 2.7 & 3.0 Litre V6
• Production start: 2003
– 3.0L Upgrade 2008
• Mature volume: 125,000 per year
• Tupy Joinville
• 3.0L: 275 ps (68 kW/l)
• 3.0L: 600 Nm from 1,900 rpm
• Jaguar, Land Rover and PSA
Peugeot-Citroën vehicles
• Euro VI compliant
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Series Production
Ford 3.6 & 4.4 Litre V8
• Production start: 2006
– 4.4L Upgrade 2010
• Mature volume: 40,000 per year
• Tupy Joinville
• 308 bhp (+15%)
• 700 Nm from 2,000 rpm (+10%)
• Range Rover, Range Rover
Sport, Land Rover Discovery
• Euro VI compliant
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Series Production
Ford USA 6.7 Litre V8
• Production start: 2009
• Mature vol: >200,000 per year
• Tupy, Brazil
• 390 bhp (290 kW)
• 997 Nm @1,600 rpm (735 ft-lb)
• F-Series Super Duty Trucks
– F-250 to F-750
• US EPA 2015 compliant
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Series Production
Hyundai 3.0 Litre V6
• Production start: 2006
• Mature volume: 100,000 per year
• Hyundai, Jeonju Foundry
• 240 horsepower (60 kW/l)
• 460 Nm from 1,700-3,500 rpm
• Hyundai Veracruz and ix55
• Kia Mohave
• Marine Applications
• Euro VI compliant
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Series Production
VM Motori 3.0 Litre V6
• Production start: 2010
• Mature volume: >150,000 per year
• Tupy Joinville, Brazil
• CGI Block and Bedplate
• 250-275 horsepower (62-65 kW/l)
• 570 Nm from 1,400 rpm
• Chrysler, Lancia & Jeep vehicles
• Ram 1500 Light Duty Pick-up
• Maserati Ghibli & Quattroporte
• Euro V and EPA 2010 compliant
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Petrol Engines
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Series Production
Ford 2.7 / 3.0L V6 Petrol Engine
• Production start: 2013
• Mature volume: >300,000 per yr
• Tupy Saltillo
• 325 ps (120 ps/l)
• 508 Nm (375 lb-ft)
• Ford F-150, Edge, Fusion
• Lincoln MKX, MKZ, Continental
• Compact short skirt CGI block
• Fracture split main bearings
• Aluminium housing to pan rail
• Open deck
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Series Production
Ford 2.7 / 3.0L V6 Petrol Engine
(Courtesy Ford)
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Series Production
Ford 2.7 / 3.0L V6 Petrol Engine
(Courtesy Ford)
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Commercial Vehicles
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SinterCast and the Market
SinterCast-CGI Heavy-Duty Engines
• DAF 12.9L ‘MX’ (block and head)
• DAF 10.8L (block and head)
• Ford Otosan 7.3L and 9.0L (block and head)
• Hyundai 3.9L and 5.9L (block)
• Hyundai 5.9L, 10.0L and 12.7L (heads)
• JMC and Ford-Otosan 9.0L block; 9 & 13L heads
• Navistar 6.4L, 10.5L and 12.4L ‘MaxxForce’ (block)
• MAN 10.5L (D20) and 12.4L (D26) engines (block)
• Scania 13L (block)
• Scania 16L (block)
©SinterCast
Series Production
DAF 12.9L Block & Head
• Production start: 2008
• Volume: 25,000 per year
• Tupy Mauá, Brazil
• 12.9 Litre MX-13 engine
– 460–510 bhp (29 kW/l)
– 2,300–2,500 Nm
• Fracture split main bearing
• Euro VI compliant
©SinterCast
Series Production
DAF 10.8L Cylinder Block
• Production start: 2015
• Volume: >25,000 per year
• Tupy Mauá, Brazil
• 10.8 Litre MX-11 engine
– 286–369 bhp
– 1,580 Nm @ 1,000-1,650 rpm
• Fracture split main bearing
• Euro VI compliant
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Commercial Vehicles
Ford-Otosan 7.3 & 9.0L Ecotorq
• Production start: 2007
• Volume: 10,000 per year
• Componenta, Turkey
• 315-350 bhp
• 1,100-1,250 Nm torque
• Parent bore
• Euro V compliant
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Series Production
Hyundai F & G Engines
• Production start: 2007
• Initial volume: 30,000 per year
• HMC Jeonju Foundry, Korea
• F Engine (3.9 L)
– 155 bhp (30 kW/l)
– 380 Nm @ 1,600 rpm
• G Engine (5.9 L)
– 230 bhp (29 kW/l)
– 590 Nm @ 1,700 rpm
• Euro VI compliant
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Series Production
Hyundai G, H and L Heads
• Production start: 2011
• Initial volume: 20,000 per year
• Daedong Metals, Korea
• G Engine (5.9 L)
– High performance versions
• H-Engine (9.9 L)
• L-Engine (12.7L)
• Power upgrades
• Durability
• Euro VI compliant
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Series Production
MAN D20 & D26 Engines
• Production start: mid-2007
• Initial volume: 25,000 per year
• Tupy Mauá, Brazil
• D20 Engine (10.5 L)
– 315–434 bhp (31 kW/l)
– 1,600–2,100 Nm
• D26 Engine (12.4 L)
– 453–532 bhp (32 kW/l)
– 2,100–2,500 Nm
• Euro VI compliant
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Series Production
Navistar MaxxForce 11 & 13
• Production start: 2007 & 2011
• Current volume: 60,000 per year
• Tupy Mauá & PurePOWER, Indy
• MaxxForce 11 (10.5 L)
– 330–390 bhp
– 1,250–1,450 lb-ft
• MaxxForce 13 (12.4 L)
– 410-475 bhp
– 1,450–1,750 lb-ft
• 275 kg less than CAT 15L engine
• US EPA 2015 compliant
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Series Production
SCANIA 13 Litre
• Production start: 2013
• Mature volume: 35,000 per year
• Scania Foundry, Sweden
• Halberg Guss, Germany
• Tupy, Brazil
• 12.7 litre, in-line 6 cylinder
• 400 - 550 horsepower
• Euro VI compliant
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Series Production
SCANIA 16 Litre
• Production start: 2010
• Mature volume: 10,000 per year
• Halberg Guss, Germany
• Power range:
– 368-537 kW
– 500–730 horsepower
• Torque range
– 2,400-3,500 Nm
– 1,765–2,575 lb-ft
• Euro VI compliant
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Industrial Power
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Series Production
Industrial Power
• Allen Diesels:
– 550 kg cylinder heads, 9-17 tonne engine frames
• Cameron Compression:
– 150-500 kg heads & turbos
• CAT cylinder heads: 3500, 3600, C175
• Cummins QSK95 95L cylinder head
• Deutz 7.8L 6-cylinder head for tractors
• Doosan 27L V12 military engine cylinder block
• EPS 4.3L, ‘Flat V8’ for general aviation
• Federal Mogul: 200-900 mm Dia. piston rings
• General Electric:
– 165 kg cylinder heads for locomotives
– Strongback support for locomotives
– 50-100 kg Jenbacher cylinder heads for natural
gas engines
• Hyundai: 3.0, 3.9, 5.9 & 9.9L marine engines
• Liebherr V8 & V12 cylinder blocks
• MTU Series 2000 cylinder heads
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Series Production
Grey Iron and CGI
• Durability for Power-up
• Same tooling & dimensional
tolerances
• Same shake-out time
• Same residual stress pattern
• Series production examples
– Hyundai 5.9, 9.9 & 12.7L Heads
– Scania 13L & 16L Blocks
– Volvo 11L Block
– Waukesha Natural Gas Head
– 200-900 mm Piston Rings
– Motorsport upgrades
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SinterCast and the Market
Market Development
61% Passenger Vehicle; 33% Commercial Vehicle; 6% ‘Other’
Largest Growth: Commercial Vehicle – 280 bar Pmax
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