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FLEXICAST - Robust, and FLEXible CAST iron manufacturing

  • 27677
  • CORDIS - PROJECTS 20/09/2012
  • RISULTATO

The FLEXICAST project presents knowledge-based technologies that aim to follow the way to transform the conventional (batch-by-batch) foundry process into a flexible (mold-by-mold) process. The proposal technologies will be applicable not only to new cast iron foundry lines, but also is readily available to be retro-fitted to existing plants. The specific objectives are:

a) A cast iron production cell. Together with melting, treatment and pouring sub processes in a cast iron production cell is essential and imperative. We propose to install the melting shop closer to the pouring system kept closed on the mould carrousel, while the transfer and treatment ladle is removed. The widespread adoption of new melting shop as an operating process is in itself fostering the creation of even more powerful induction-plasma power supplies, versatile melt control technology, high-power density furnaces, temperature control systems, nodularization systems(magnesium vapour), inoculation systems, and automated pouring systems.

b)Integration of Artificial Intelligence-based Control System. The objective is to develop a software platform. This can help us to the prediction of local structures, phases and ultimately the local mechanical properties, to asses casting quality in the foundry. In this point, also, three specific methodologies will be studied and improved: DTA analysis and on-line microstructural analysis and X-ray for on-line inspection.

c) A robot cell for automated metal finishing processes.

d) Demo pilot plant in real industrial settings in order to demonstrate a clear breakthrough using project development in comparison with the state-of-art solutions.

Some results are:
a) Cast iron manufacturing cell represents, at least, 30% energy reduction in comparison with conventional melting systems.
b) Drastic reduction melt temperature scattering during molding process. Reduce metal transport (No transfer and treatment ladles).
c) Overheating reduction.
d) Reduce rejection of casting pieces.


Start date: 2012-11-01
End date: 2016-10-31

Duration: 48 months

Project Reference: 314540

Project cost: 9249664 EURO
Project Funding: 5700000 EURO

Subprogramme Area: Innovative technologies for casting, material removing and forming processes
Contract type: Collaborative Project targeted to a special group (such as SMEs)


Coordinatore: UNIVERSITAT POLITECNICA DE CATALUNYA - Valenti GUASCH (Mr)

Altri Partecipanti

  • INNOSPEXION APS -(DANMARK)
  • FUNDACIO PRIVADA ASCAMM - (ESPAÑA)
  • CONSIGLIO NAZIONALE DELLE RICERCHE - (ITALIA)
  • FUNDICIONES DE RODA S.A. (ESPAÑA)
  • POZNAN UNIVERSITY OF TECHNOLOGY - (POLSKA)
  • COMAU SPA -  (ITALIA)
  • FUNDACION TECNALIA RESEARCH & INNOVATION - (ESPAÑA)
  • CENTRE INTERNACIONAL DE METODES NUMERICS EN ENGINYERIA - BARCELONA (ESPAÑA)
  • TRELLEBORG SEALING SOLUTIONS ITALIA SPA - (ITALIA)
  • ONDARLAN S L - (ESPAÑA)
  • ARC SRL - (ITALIA)
  • PROSERVICE SRL -  (ITALIA)
  • SERT-METAL SAS - (FRANCE)
Link
Quadro di finanziamento
  • 7FP-NMP : NANOSCIENZE, NANOTECNOLOGIE, MATERIALI E NUOVE TECNOLOGIE DI PRODUZIONE: priorità tematica 4 nell'ambito del programma specifico “Cooperazione” recante attuazione del Settimo programma quadro (2007-2013) di attività comunitarie di ricerca, sviluppo tecnologico e dimostrazione
Area di interesse
  • Unione Europea