Tecnalia - Foundry Unit Projects

Examples of projects of foundry unit

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INDUSTRY REFERENCES

Boeing Airbus EADS AernnovaRenault PSA Wolkswagen HondaFIAT KYB Grupo Antolin HispacoldCAF Irizar Cie Automotive FagorEnterprise Bravo INAUSA Nicolás Correa MTorresAlcoa Aleastur J.L. French AnsolaBefesaFoseco Alumalsa Bostlan DalphimetalEnv. Met. Alava Acciona WindpowerOrbea Bicicletas Alcatel EspacioESA CMD Ferroli FIASALoramendi Mapsa Ronal Ibérica CESASammic Air Liquide Praxair TafimeTeleves VALEO Schindler DaciaAsturiana del Cinc Aurrenak I. Lebario

HydroGrupo Abengoa Böhler uddeholm Comp. Vilanova FiasaCemex Ferroli Hormesa Gis 2003Insertec HUF España Guinea Hnos……………

The Division carries out R&D on technologies involved in the manufacturing and life cycle of The Division carries out R&D on technologies involved in the manufacturing and life cycle of a product: material development & modification, design & engineering, manufacturing a product: material development & modification, design & engineering, manufacturing processes, maintenance, after sale, disassembling, recycling and impact on the processes, maintenance, after sale, disassembling, recycling and impact on the environment: environment:

MaterialsMaterialsMaterialsMaterialsModelling, Modelling, Design & Design &

EngineeringEngineering

Modelling, Modelling, Design & Design &

EngineeringEngineering

ManufacturinManufacturing Processg Process

ManufacturinManufacturing Processg Process

Post- Post- processing &processing &Testing rigsTesting rigs

Post- Post- processing &processing &Testing rigsTesting rigs

Disassembly Disassembly / Recycling & / Recycling & environmentenvironment

Disassembly Disassembly / Recycling & / Recycling & environmentenvironment

• Nanostructured & nanocomposite materials.

• MMC & OMCs.• New alloys and materials (e.g by SHS)

• High T materials.• Cellular materials.

• Coatings (thin, thick) & surface treatments.

• . . . . . . . . . . .

• Nanostructured & nanocomposite materials.

• MMC & OMCs.• New alloys and materials (e.g by SHS)

• High T materials.• Cellular materials.

• Coatings (thin, thick) & surface treatments.

• . . . . . . . . . . .

• Predictive simulation.

• Proc. modelling.• Design for weight reduction.

• Ecodesign.• Process & equip. eng. (e.g. friction stir welding , thermal spraying, drilling & cutting, pick & place, etc.)

• ..........

• Predictive simulation.

• Proc. modelling.• Design for weight reduction.

• Ecodesign.• Process & equip. eng. (e.g. friction stir welding , thermal spraying, drilling & cutting, pick & place, etc.)

• ..........

• Metal casting (Ferrous & Non-ferrous alloys).

• Steelmaking• MMCs, plastic & OMC processing.

• Cutting, Forming.• Powder Metall.• Welding & Joining.• Surface Eng. (esp. Thermal Spraying)

• Clean processing.• . . . . . . . . .

• Metal casting (Ferrous & Non-ferrous alloys).

• Steelmaking• MMCs, plastic & OMC processing.

• Cutting, Forming.• Powder Metall.• Welding & Joining.• Surface Eng. (esp. Thermal Spraying)

• Clean processing.• . . . . . . . . .

• Surface Finishing and cleaning.

• Coatings.• Heat Treatments• Cr, Cd free treatm. & coat.

• Integral maintenance & after sale service.

• Advanced testing rigs.

• . . . . . . . .

• Surface Finishing and cleaning.

• Coatings.• Heat Treatments• Cr, Cd free treatm. & coat.

• Integral maintenance & after sale service.

• Advanced testing rigs.

• . . . . . . . .

• Selective extraction of materials from industrial waste.

• Waste to energy valorization.

• Recycling and valorization of end-of-life products.

• Automatized disassembling.

• .........

• Selective extraction of materials from industrial waste.

• Waste to energy valorization.

• Recycling and valorization of end-of-life products.

• Automatized disassembling.

• .........

European project that responds to the need of foundry sector to seek solutions to the problem of the emission of dioxines , generated by the usual melting processes during casting of ferrous metals.

Impact•Reduction of the emission of diioxines.

Heating system for casting laddlesPatent with priority date 23-12-99 (“New casting furnace for moulding”) led to a family of patents granted in another 8 countries: USA, Russia, Japan, Korea, France, Germany, Great Britain and Italy.

Sale in December 2007 of an exclusive licence for exploitation of the technology to SERT-METAL (France).

Income of 6 to 9 Million € over the next 10 years from royalties for the sale of installations.

REFERENCES for the European Project

REFERENCES for the European Project

The general objective of EDEFU project consists on investigating, developing and to validate with prototypes on scale, new technologies of heating, development of new materials to improve the heat insulations, new efficient designs and innovating recovery systems of residues generated in the own one make, so that they can allow the main consuming industries of energy, the beginning of a new era of eco-efficient companies.

The ratification of the success of the project will be demonstrated through the validation carried out with 4 demonstrators developed and implemented using new technologies for the sector involved in the project: Foundry, Glass, Cement and Ceramic. Quantified technical targets will reach

• 20% reduction in power consumption based on different process assessments

• the null particle emission to the atmosphere through own integration in the process

• the transformation of heat loses in other exploitable energies • the reduction in at least 50% in the generation of wastes through innovating

recovery system of wastes of internal form • and the reusability of the 100% of the generated CO

http://edefu.eu/english



MELTING

Transfer ladle

Main target of PLASMAPOUR: Energy Efficiency & Metallurgical Quality

MELT COLD POUR HOT

Less energy consumption Less oxidation Less refractory consumption

To ensure correct metallurgical quality

To avoid defects linked the pouring temperatures

POURING

PLASMA ACTION

Temperature adjusting at the right pouring

moment

INDUSTRIAL INSTALLATIONSLINGOTES ESPECIALES- SpainDisk brake manufacturer

Plasma embedded on a tundish Capacity 3 Ton. Grey iron Instalation: September 2010

Without plasma heater temperature drop down 3°C per minute

With plasma heater temperature stabilized

Refilling

FUCHOSA- SpainBrake forks manufacturer

Plasma embedded on a pressurized furnace with inductor. (Hybride option)

Capacity 8 Ton. Ductile iron Instalation: September 2009

WITHOUT WITH PLASMA DIFFERENCE

Quantity of mold poured 4756 4335

% of mould poured at +/-3°C / set point 1.14% 62.00% + 60.86%

% of mould poured +/-5°C/ set point 9.89% 82.00% + 72.11%

% of mould poured +/-10°C/ set point 32.13% 97.00% + 64.88%

% of mould poured < - 10°C/ set point 73.00% 1.70% - 71.30%

% of mould poured > 10°C/ set point 2.80% 1.10% - 1.70%

MAGNMAGNO O

2008-20122008-2012MAGnesium New Technological Opportunities

• Promote the Metal Sector in Spain through a program of investment in high technology

• Get more knowledge and technologies on metallurgy, processing and finishing of magnesium

• Put Spain in the top of a futures market to trend upward.

• Spanish Consortium to strengthen competitiveness based on technology and knowledge and strategy aligned with the European R & D of seven framework.

• 18 industrial partners and 20 technological centers and universities

• Budget: 32.000.000 € - Tecnalia: 5,000,000€

ECOFOND

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EQUIPMENT AND PILOT PLANTSEQUIPMENT AND PILOT PLANTS

• Sand Casting and gravity casting• High pressure Die Casting for aluminium and magnesium.• Lost foam.• Different melting furnace. Rotative, induction resistance• New Rheocasting of aluminium and magnesium.• Squeeze casting direct, investment casting, Plaster casting and centrifugal

casting• Mould with sensors to gas, contact metal, etc.• Simulation of process: PROCAST y SALSA.

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FACILITIES: pilot plant

Lost foam

HPDCSqueeze casting DirectThixocasting

Sand Gravity MATERIALS: AluminiumMagnesium, Titaniun

Copper, zic, Steel, iron alloy

Mechanical characterization (universal Machines of test, creep, impact, tests under cryogenic conditions, to room temperature and high temperatures, dynamic, fatigue)

FACILITIES: Laboratories

Microstructural characterization (optical Microscopes, SEM, Image analysis, EDS, WDS, EBSD, XPS, Auger, Gleebe 3800, etc.)

FACILITIES: Laboratories

Chemical analysis, corrosion

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CASTPRESS: a laboratory for pressure die casting in

Tecnalia - Foundry

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Instalations:

Machine 950 Tn, melting and heating furnaces for Al and Mg, automatic feeder, refrigeration and lubrification systems and

Semisolid processing machine (Thixo & Rheocasting).

Type of research projects carried out: Life improvement of moulds and dies. (Investigating on diferent materials and

treatments / coatings and testing them in a special thermal fatigue testing machine.

Study of process innefficiencies. Testing on moulds. R&D and testing of new non-ferrous alloys for pressure die casting to improve

their properties. R&D of new semi-solid technologies. (Development of proper alloys for the

transformation of material in a semisolid-state and development of new processes for the preparation and injection of semi-solid materials).

Improvement of machines and pressure die casting equipment.

Type of research projects carried out: Life improvement of moulds and dies. (Investigating on diferent materials and

treatments / coatings and testing them in a special thermal fatigue testing machine.

Study of process innefficiencies. Testing on moulds. R&D and testing of new non-ferrous alloys for pressure die casting to improve

their properties. R&D of new semi-solid technologies. (Development of proper alloys for the

transformation of material in a semisolid-state and development of new processes for the preparation and injection of semi-solid materials).

Improvement of machines and pressure die casting equipment.

REFERENCES for the Foundry INDUSTRY

OTHER EXAMPLES OF PROJECTS DEVELOPED

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Rectangular blocks (200x80x80 mm3) of foamed Al used for further production of foam Al sandwich structures made of an inner foam core and an outer Al dense skin (6 mm thickness) by LPC technique.

Injection parameters controlled to avoid any deformation of foam insert.

Other technologies also applied to produce these sandwiches such as SC or HPDC but the high pressures involved in these technologies can lead to foam damage or even penetration of molten aluminium in the own inner foam structure.

Production of components with foamsProduction of components with foams

Low Pressure die casting (LPDC) device for the production of aluminium foam sandwich structures. On the left, the principle of the LPDC process is described. On the right hand side, an industrial LPDC device together with a mould and a detail of a foam insert are shown

CLOSED CELL METAL FOAMSCLOSED CELL METAL FOAMS


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Alloying tabletsAlloying tabletsAlloying tabletsAlloying tablets

Cylindrical alloying tablets of 90 mm diameter and different heights according to different densities and alloying metal contents in the composition

Tablets contain from 75% of alloying element, and are usually available in units of 500 g or 1 Kg of metal. The balance can be made up of pure aluminium, non-hygroscopic sodium free flux, or a mixture of both components.

The tablets are wrapped in plastic or aluminium foil sleeves of 3 to 5 units packed into cardboard boxes, each one containing usually 6 sleeves. Both sleeves and boxes show the description of the product, and they are colour coded for easing the identification of the alloying element.

The company provides other alloying metals, weights, sizes, packaging and/or specifications: Mn Tablets, Cu, Fe, Ti, Cr, Ni.

Cylindrical alloying tablets of 90 mm diameter and different heights according to different densities and alloying metal contents in the composition

Tablets contain from 75% of alloying element, and are usually available in units of 500 g or 1 Kg of metal. The balance can be made up of pure aluminium, non-hygroscopic sodium free flux, or a mixture of both components.

The tablets are wrapped in plastic or aluminium foil sleeves of 3 to 5 units packed into cardboard boxes, each one containing usually 6 sleeves. Both sleeves and boxes show the description of the product, and they are colour coded for easing the identification of the alloying element.

The company provides other alloying metals, weights, sizes, packaging and/or specifications: Mn Tablets, Cu, Fe, Ti, Cr, Ni.

Industrial validation of Al alloying tablets


Manufacturing of die pressure casting moulds by “Stratoconception” and brazing

Manufacturing of die pressure casting moulds by “Stratoconception” and brazing

Process descriptionProcess description

• Fabrication of moulds by stratification and brazing.

• Optimized the brazing process without high vacuum with cost-saving.

• Validated the process under pressure die casting and gravity casting with repetitive results.


Design and optimization of automotive components

Design and optimization of automotive components

Need:To adequate Al material and process to the performance required, looking for the best properties.Know how:•Knowledge of processes (e.g. high P die casting, gravity with sand and metallic mould, low P, Thixocasting , Squeeze Casting, etc)•Characterization , materials properties and properties required to meet end-use industrial specifications.Results of the project:•Technological mapping (material, process, properties, end use applications)


Need

SolutionAfter validation on the OCAMICA test benches, the product was presented at several international trade fairs with satisfactory results, allowing the client to penetrate new markets.

All the production is currently sent to France, the United Kingdom, Ireland, Norway, etc.

Traditional lock screws are made from spheroidal cast iron and their design has changed little over the years.

OCAMICA Hnos, the company manufacturing the lock screw, is collaborating with TECNALIA to develop a new product with the sole limitation of the minimum resistance it has to withstand. This product is widely used in construction, workshops, etc.

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Optimization and improvement of the Lock Screw

(design for aluminium)

Optimization and improvement of the Lock Screw

(design for aluminium)


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Development of an intelligent T control system for the mould .NEED: •Self-regulation of refrigeration and lubrification of high pressure die casting molds as a function of internal and external T and automatic data saving.•Important for moulding company, to obtain all information relative to performance of mould.KNOW – HOW & SOLUTION:•Mold Design & simulation experience, know how in refrigeration and lubrication systems and development of taylored control solutions •Development of an intelligent management and control algorithm of the mold by a PLC.

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Hora

Tª Serie1

Serie2

Infrared Infrared measuremmeasurem

entent

Thermocouple

measurement

Intelligent control

T Inputs

Internal and external

refrigeration

Calculated output of

refrigeration times

PLC


CASTPRESS: Case 2 ProjectCASTPRESS: Case 2 ProjectEndurance of die casting moulsNEED: •Improve lifetime of molds in high pressure die casting.KNOW – HOW:•Materials and their behaviour under extreme conditions.•Surface thermochemical treatments and coating technologies.•Design and development of new testing concepts.SOLUTION: •Design and development of a thermal fatigue testing machine.•Selection of best combination of material and surface treatment.

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Technology

Target

Applications

CASTING of LIGHT MATERIALS: Aluminium and Mg

CASTING of LIGHT MATERIALS: Aluminium and Mg

ALUMINIUM: Products: Brake disk, Piston, Cylinder Head, Callyper

MAGNESIUM:(Projects Starting December 2008) Products: Seat Frame, Steering Wheel, Instrument panel carrier

Weight Reduction and High Performance

ALUMINIUM: Gravity Casting, Investment/Lost Wax Casting , Lost Foam (Sand / Magnetic moulding - Steel Shots), HPDC, Squeeze Casting, Plaster Casting

MAGNESIUM: Gravity, Investment / lost wax, Lost Foam (Sand), HPDC (Projects Starting December 2008)

Know-How

Material development, characterization and process


CASTING: Al-MMCs (Aluminium Matrix Composites)


Manufacturing prototypes of an automotive component (brake drum) in a composite material and the fine tuning of the different forming technologies: gravity metal mould casting, sand mould casting and Squeeze Casting.

These composites are known for their high wear resistance, excellent mechanical properties at average in-service temperatures and their heat conductivity.

Need

SolutionComparison of the results of the metal mould and sand mould techniques shows the former to be best: a smaller grain size is achieved, as well as reduced porosity, giving improved mechanical properties that can be improved by subsequent heat treatment.

Specific industrial applications for automotive components: brake discs and drums, clutch discs, cylinders and pistons.

Squeeze Casting ProcessSqueeze Casting Process

Brake drum Brake drum (Courtesy of Fagor Ederlan)(Courtesy of Fagor Ederlan)

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Material:

Al/TiB2 composites produced by “in situ” methods

Improvements:

Wear, Low CTE, lightness and mechanical properties at high temperatures

Aplications:

Clutch discs, pistons and railway brake discs

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Material:

Al/Al2O3 and Al/SiCp Composites

Aplications:

Clutch discs and ventilated brake discs

LOCAL REINFORCEMENT

Improvements:

Wear, Lightness, Low CTE and Mechanical Properties at high temperatures

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Chemical Conversion Coatings

Chemical Conversion CoatingsChromium free conversion coating

Patents: WO2008094193, EP1887105F.J. Cano, U. Izagirre, O. Zubillaga, P. Santa Coloma, 13/02/2008

• Based on conducting polymers and zirconates.

• Aluminium alloys

SSF Tested panels 2024 T3 alloy – 336 hoursSSF Tested panels 2024 T3 alloy – 336 hours

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AnodisingAnodisingChromium free Chromium free anodising based on nanoparticles and conducting polymers Patent: PCT/ES 2008/000056 F. J. Cano, O. Zubillaga, G. Imbuluzketa, I. Azkarate

• Based on oxalic acid, conducting polymers and nanoparticles.

• Aluminum alloys

TEM cross section

Anodic oxide layer: 2.7 microns

Nanoparticles top layer: 150nm

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Thermal Spraying : Development of technology & equipment (3 of 3)

Protection of Al moulds with wear & corrosion resistant

coatings

Protection of Al moulds with wear & corrosion resistant

coatings

SeeSee VideVide

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SeeSee VideVide

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Coquilleuse équipée de deux outillages.

Outillage revêtu du dépôt PVD - CrAlN

Outillage revêtu de poteyages

conventionnels.

Permanent wear resistant coatings for die casting and low pressure injection molding of Al parts (I)

Permanent wear resistant coatings for die casting and low pressure injection molding of Al parts (I)Development of permanent or semi-

permanent coatings produced by PVD (Physical Vapour Deposition), with a wear life significantly higher (min. x 4-6 times) than traditional demoulding agents and avoiding or minimising their problems.

Work consisted on:

•Study on compatible coatings with die casting molds and dies able to improve performance of actual solutions.

•Optimizing PVD processes for the present industrial application.

•Establishment of procedures for its application on moulds.

•Industrials tests with the new coatings.

•Cuantify the improvement and define possible applications.

•These coatings shall improve availability and productivity of moulds.


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Permanent wear resistant coatings for die casting and low pressure injection molding of Al parts (II)

Permanent wear resistant coatings for die casting and low pressure injection molding of Al parts (II)

Ejection des grappes de coulée.Après 150 cycles, aspect du dépôt PVD-CrAlN sur la broche centrale.


Solid lubricant coatings on Al parts (by PVD Technology)

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Novel solid lubricant coating based on MoS2 on Al pistons (2 stroke engine) to reduce friction (under conditions of reduced oil-petrol mixture) reduced friction and emissions.

• Reduction of oil content in petrol–oil mixture Reduction of oil content in petrol–oil mixture reduced emisions reduced emisions(from 1,5 to 0,3% oil reduction (from 1,5 to 0,3% oil reduction 15% reduction in hidrocarbons, 10% in CO, 10% in 15% reduction in hidrocarbons, 10% in CO, 10% in visible smoke)visible smoke)

• Solid lubrication in contacting surfaces to counteract loss of liquid lubrication.Solid lubrication in contacting surfaces to counteract loss of liquid lubrication.• Hard wear resistant coating + outer solid lubricant, to extend wear life.Hard wear resistant coating + outer solid lubricant, to extend wear life.

Example: Production of Al powder from Al/plastic film waste

Example: Production of Al powder from Al/plastic film waste

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Aluminium / plastic film waste from discarded packaging (e.g. for food, cosmetics, etc.) is transformed by means of a propietary process into two valuable products: Aluminium powder and heat.

Aluminium powder:•94-97% pure Al, 1% Fe residual•150 – 500 µm powder size

Heat:•By product gas as a result of the combustion of plastic: with a calorific value of 7000 kcal/m2 (lower than natural gas 9000 kcal/m2)

Al coated plastic film waste

Successful industrial trials carried out with: exothermic sleeves & Al exothermic sleeves & Al tabletstablets
