Innovation & Technology

The knowledge base of Tupy comes from metallurgy. Over the years, thinking in the properties of metals and other materials, and their application in the market enabled us to perform in diversified applications and segments, identifying the needs and connecting them to our technical and technological skills.

The products developed by Tupy are customized to meet the needs of each individual customer. More than investing in technology, we invest in our employees qualification and development.

Cooperation with customers

Produced in compliance with the customers’ specifications, the structural components result from the work of specialized professionals.

Product development engineering

We develop technologies for cast, machined and mounted metallurgical products with high technical requirements, observing the industry trends. With renowned professionals in the global casting scenario, Tupy stands out in the creation of new materials and technologies. We rely on prepared engineering of materials and dimensions to support the whole capital goods industry. We work in design and suggest the best alternatives with the customer, with aid of design and simulation equipment and software components.

Leading technology

Tupy is acknowledged as a leader in technology for the last generation of engines (light weight - thin wall, complex geometry, high-strength materials):

Experienced technical team; Highly qualified manpower;
Excellence in the development of new casting processes;
Global reference producer of Engine Blocks and Cylinder Heads in several metallic alloys, highlighting CGI.

Development of processes aimed to improvement of efficiency and quality

Co-design to product performance monitoring with on-site engineers and assistant technicians in the customers;
Product and process simulation systems;
Prototyping via additive manufacturing;
Process control and product traceability control systems;
Improvement and evolution of the product and quality processes using AI concepts and technology;

Metallurgy

Over the years, the company has developed several partnerships with world-renowned technical institutes and universities, in the conception of new materials and metallurgical processes, enabling the offering of innovative solutions related to:

- Mechanical and thermal properties
- Dimensional precision
- Energy efficiency

Combined with the items above, its installations are prepared to support products with wide range of materials, dimensions, weights and requirements, making it a company extremely responsive and flexible in terms of production capacity and geography.

Compacted Graphite Iron – CGI

Tupy is the first casting plant in the world to produce Compacted Graphite Iron (CGI) iron in large scale. CGI provides higher mechanical strength than gray cast iron, traditionally used in engine blocks.

Tupy Tracker + Artificial Intelligence

The Tupy traceability project has the aim of detailing the history of process variables which are important for the final result of the product, thus assuring speed and precision in decision-making:

Process control system in each phase;
Integration of technologies for process traceability with the cast part;
Full traceability of products and processes;
Follow-up and monitoring of production process variables on time;
Integration between process variables and the final result of the product;
Improvement and evolution of the product and quality processes using Artificial Intelligence concepts and technology

Compacted Graphite Iron – CGI

Graphite is present in the form of compact veins, interconnected, with some nodular-shaped graphite particles. These characteristics provide the material with superior mechanical properties when compared to gray cast irons, without any thermal conductivity losses.

The increase in mechanical strength is up to 75% in relation to gray cast irons, 35% to 40% more in the modulus of elasticity, and almost double increase in the fatigue limit.

Thus, CGI arises to meet the demand for materials with higher mechanical strength, replacing the gray cast iron in the new diesel engines of better performance. Operating under greater pressure and temperature, these new engines require superior mechanical properties from the constructive materials than those of conventional iron. Due to these characteristics, compacted graphite iron enables the construction of smaller, more efficient and less polluting engines. With the aim of being a development casting operation as one of its key characteristics, still in this class of material, the company is capable to offering enhancements in specific properties, which may promote higher performance of its customers’ products.

Tupy UP

Convert, speed up and scale up opportunities in new businesses and promote improvements in the existing ones, by innovation and digital transformation.

Open innovation

Tupy believes that getting different experiences and skills together in a collaborative way generates sustainable value. For us, Open Innovation strengthens the ecosystem of science, technology and innovation, co-creating and catalyzing potentials throughout the network.

Check out our challenges here

Startup acceleration

Attention, entrepreneurs! Tupy has a Startup Accelerator with differentiated proposal. With a group of mentors specialized in several industry areas and respect to intellectual property and talents of startups, ShiftT was born – it is an accelerator that values collaboration and mutual benefit for Tupy, startup and ecosystem. Visit the ShiftT website and get to know the acceleration program.

Visit website: www.shiftt.com.br

Research & Development

To develop new products, process knowledge is another key differential of Tupy, which combines scientific competence in metallurgy and hands-on casting knowledge. Our research team relies on the support of proper labs and partnerships established with universities worldwide. In the search for solutions to the industry challenges, we meet with efficacy the demands for new materials and the increasing use of inputs more efficiently.

Tupy Tech

Focused on disruptive R&D projects for opportunities that can gain market emphasis and be scalable. For more information tech@tupy.com.br

Manufacture

Our production process in details

Before production, the Engineering and R&D teams develop projects together with our customers.

1.
Casting

Casting is the transformation of the major inputs in cast iron alloys. Raw materials are inserted into cupola, induction and arc furnaces, where they are changed to molten metal at temperatures above 1500ºC.

2.
Core shop

Making cores means the obtainment of sand and resin (“core”) agglomerates, which are molds that shape the part cavities and recesses. “Cores” are fitted in a single set, which will receive the molten metal upon pouring.

3.
Molding

It is the process for preparing the sand mold (silica, bentonite, powdered coal, water) by compression against a die (“tooling”) resulting in a negative replica, which will provide the outer shape of the part.

4.
Pouring

Once the flask is obtained with the “core” and mold prepared, pouring process starts. The metal alloy is “poured” in the core-mold set, where it fills all the cavities, reaching the “tooling” form.

5.
Finishing

In this stage, the cast part is submitted to steel shot blasting to remove sand and minor metallic burrs. Next, it passes by quality control inspection according to the customers’ specifications.

6.
Machining

Machining is a phase carried out after finishing, Where the final dimensions and geometry of the product are checked, enabling its interfaces and assemblies. This stage can be performed at the customer or Tupy premises.

Casting

Core shop

Molding

Pouring

Finishing

In this stage, the cast part is submitted to steel shot blasting to remove sand and minor metallic burrs. Next, it passes by quality control inspection according to the customers’ specifications.

Machining

Library

Tupy not only searches for knowledge, especially with universities and research centers, but also generates knowledge. Listed below are some works published or disclosed by professionals that are members of the technological areas in the company, which can be accessed in PDF or DOC format.

Avaliação do uso de modelos produzidos por estereolitografia na fundição em moldes de areia aglomerada por resinas do tipo caixa fria fenólicouretano

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Innovation & Technology

Cooperation with customers

Product development engineering

Leading technology

Development of processes aimed to improvement of efficiency and quality

Metallurgy

Compacted Graphite Iron – CGI

Tupy Tracker + Artificial Intelligence

Tupy UP

Open innovation

Startup acceleration

Research & Development

Tupy Tech

Manufacture

1. Casting

2. Core shop

3. Molding

4. Pouring

5. Finishing

6. Machining

Library

SIMEA 2022 - Ultra Light Iron Block e Etanol

SIMEA - 2022 - tempo de solificação

Paper SAE BR 2022 Reciclagem de Baterias

International Engine Congress Paper 18 Ferrarese

Vienna 22 - Ultra Light Iron Block

Breakthrough: new Bosch diesel technology provides solution to NOx problem

The Importance of Gas Infrastructure for the German Energy Transition

Wrong to Discourage Purchase of Diesel Cars (SRASEC)

Zero CO2 Powertrains in Comparison of Tank-to-Wheel and Well-to-Wheel Balance

Folded Metal and Other Surface Parameters on Combustion Engine Cylinders

Analysis of wear of cemented carbide cutting tools during milling operation of gray iron and compacted graphite iron

Ferro nodular austemperado a partir da zona crítica

ADI Engrenagens

Avaliação da qualidade Metalúrgica

Moldes de Vidro

Usinabilidade CGI e FC cabeçotes

Análise Técnica dos Resultados de Laboratório da Aplicação da Areia Descartada de Fundição (ADF) em Obras Rodoviárias

Avaliação do uso de modelos produzidos por estereolitografia na fundição em moldes de areia aglomerada por resinas do tipo caixa fria fenólicouretano

Coletores de Escape em Nodular SiMo

Compacted Graphite Iron for Diesel Engine Cylinder Blocks

Desenvolvimentos recentes em ferros fundidos aplicados à indústria automobilística

Desgaste de ferros fundidos usados em discos de freio de veículos automotores

Fatigue strength of gray iron and compacted graphite iron used for engine cylinder blocks

Ferro fundido com grafita compacta

Ferros Fundidos Empregados para Discos e Tambores de Freio

Influência da Carga de Frenagem na Resistência ao Desgaste de Ferros Fundidos Usados em Discos de Freio

Maquinado de perfiles continuos en hierro fundido nodular FE-50007

Nitretação iônica de ferro fundido nodular

O uso da simulação do processo de fundição no desenvolvimento de peças em ferro fundido nodular

Producing As-Cast Ferritic Nodular Iron for Safety Applications

Production Experience With Compacted Graphite Iron Automotive Components

Reutilização de areia regenerada termicamente

Study of the Machinability of Compacted Graphite Iron for Drilling Process

Thermal Conductivity of gray iron and compacted graphite iron used for cylinder heads

Torneamento de Discos de Freio: Avaliação da Topografia da Superfície e do Fenômeno Open Grain

Usinabilidade de perfis contínuos de ferros fundidos nodulares das classes FE-45012 E FE-50007

Wear resistance of cast irons used in brake disc rotors

Análise da usinabilidade de ferros nodulares produzidos por fundição contínua

Surface changes during turning of grey cast iron

THE NEW GENERATION OF ENGINES AND THE CHALLENGES FOR THE FOUNDRY INDUSTRY

Three-dimensional reconstruction of compacted graphite in vermicular cast iron by manual serial sectioning

Stiffness and vibration damping capacity of high strength cast irons W. L. Guesser, L. P. R. Martins

The effect of oxide and tribofilm formation on the wear of cylinder bores from flex-fuel engines

Folded Metal and Other Surface Parameters on Combustion Engine Cylinders

Folded Metal and Other Surface Parameters on Combustion Engine Cylinders

Simulation of piston ring/cylinder bore system using tribotests – A review focused on the tribochemical aspect

1.
Casting

2.
Core shop

3.
Molding

4.
Pouring

5.
Finishing

6.
Machining