Tecnalia - Foundry Unit Projects


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  • Ampliación del Nº de residuos que actualmente reciclan.
  • Tecnalia - Foundry Unit Projects

    1. 1. Examples ofprojects offoundry unit
    2. 2. INDUSTRY REFERENCESBoeing Airbus EADS AernnovaRenault PSA Wolkswagen HondaFIAT KYB Grupo Antolin HispacoldCAF Irizar Cie Automotive FagorEnterprise Bravo INAUSA Nicolás Correa MTorresAlcoa Aleastur J.L. French Ansola BefesaFoseco Alumalsa Bostlan DalphimetalEnv. Met. Alava Acciona Windpower Orbea 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……………
    3. 3. The Division carries out R&D on technologies involved in the manufacturing and life cycle of a product: material development & modification, design & engineering, manufacturing processes, maintenance, after sale, disassembling, recycling and impact on the environment: Modelling, Modelling, Post- processing Post- processing Disassembly // Disassembly Manufacturing Manufacturing Materials Materials Design & Design & & & Recycling & Recycling & Process Process Engineering Engineering Testing rigs Testing rigs environment environment• Nanostructured & • Predictive • Metal casting • Surface Finishing • Selective nanocomposite simulation. (Ferrous & Non- and cleaning. extraction of materials. • Proc. modelling. ferrous alloys). • Coatings. materials from• MMC & OMCs. • Design for weight • Steelmaking • Heat Treatments industrial waste.• New alloys and reduction. • MMCs, plastic & • Cr, Cd free treatm. • Waste to energy materials (e.g by • Ecodesign. OMC processing. & coat. valorization. SHS) • Process & equip. • Cutting, Forming. • Integral • Recycling and• High T materials. eng. (e.g. friction • Powder Metall. maintenance & valorization of end-• Cellular materials. stir welding , • Welding & Joining. after sale service. of-life products.• Coatings (thin, thermal spraying, • Surface Eng. (esp. • Advanced testing • Automatized thick) & surface drilling & cutting, Thermal Spraying) rigs. disassembling. treatments. pick & place, etc.) • Clean processing. •. . . . . . . . • .........•. . . . . . . . . . . • .......... •. . . . . . . . .
    4. 4. REFERENCES for the European ProjectEuropean project that responds to the need of foundry sectorto seek solutions to the problem of the emission of dioxines ,generated by the usual melting processes during casting offerrous metals.Impact•Reduction of the emission of diioxines. Heating system for casting laddles Patent 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.
    5. 5. REFERENCES for the European ProjectThe 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
    6. 6. Main target of PLASMAPOUR: Energy Efficiency & Metallurgical Quality Transfer ladle POURING MELTING MELT COLD POUR HOT PLASMA ACTION To ensure correct Less energy consumption Temperature adjusting metallurgical quality Less oxidation at the right pouring To avoid defects linked the Less refractory consumption moment pouring temperatures
    7. 7. INDUSTRIAL INSTALLATIONSLINGOTES ESPECIALES- Spain Plasma embedded on a tundish Capacity 3 Ton.Disk brake manufacturer Grey iron Instalation: September 2010Without plasma heater temperaturedrop down 3°C per minute Refilling With plasma heater temperature stabilized
    8. 8. FUCHOSA- Spain Plasma embedded on a pressurized furnace with inductor. (Hybride option)Brake forks manufacturer 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%
    9. 9. MAGN 2008-2012 MAG N nesium ew Technological Opportunities O• 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. ECOFOND• 18 industrial partners and 20 technological centers and universities• Budget: 32.000.000 € - Tecnalia: 5,000,000€
    10. 10. EQUIPMENT 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.
    11. 11. FACILITIES: pilot plant Sand Gravity MATERIALS: Aluminium Lost foam Magnesium, Titaniun Copper, zic, Steel, iron alloy HPDC Squeeze casting Direct Thixocasting
    12. 12. FACILITIES: Laboratories Mechanical characterization (universal Machines of test, creep, impact, tests under cryogenic conditions, to room temperature and high temperatures, dynamic, fatigue)
    13. 13. FACILITIES: Laboratories Microstructural characterization (optical Microscopes, SEM, Image analysis, EDS, WDS, EBSD, XPS, Auger, Gleebe 3800, etc.) Chemical analysis, corrosion
    14. 14. REFERENCES for the Foundry INDUSTRY CASTPRESS: a laboratory for pressure die casting in Tecnalia - Foundry 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.
    16. 16. REFERENCES for the Foundry INDUSTRY CLOSED CELL METAL FOAMS Production of components with foams • 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.Low Pressure die casting (LPDC) device for the production of aluminium foam sandwichstructures. 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
    17. 17. REFERENCES for the Foundry INDUSTRY Alloying tablets Industrial validation of Al alloying tabletsCylindrical alloying tablets of 90 mm diameter anddifferent heights according to different densitiesand alloying metal contents in the compositionTablets contain from 75% of alloying element, andare usually available in units of 500 g or 1 Kg ofmetal. The balance can be made up of purealuminium, non-hygroscopic sodium free flux, or amixture of both components.The tablets are wrapped in plastic or aluminiumfoil sleeves of 3 to 5 units packed into cardboardboxes, each one containing usually 6 sleeves. Bothsleeves and boxes show the description of theproduct, and they are colour coded for easing theidentification of the alloying element.The company provides other alloying metals,weights, sizes, packaging and/or specifications: MnTablets, Cu, Fe, Ti, Cr, Ni.
    18. 18. REFERENCES for the Foundry INDUSTRY Manufacturing of die pressure casting moulds by “Stratoconception” and brazingProcess 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.
    19. 19. REFERENCES for the Foundry INDUSTRY Design and optimization of automotive componentsNeed:To adequate Al material and process to theperformance 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 andproperties required to meet end-use industrialspecifications.Results of the project:•Technological mapping (material, process,properties, end use applications)
    20. 20. REFERENCES for the Foundry INDUSTRY Optimization and improvement of the Lock Screw (design for aluminium)NeedTraditional lock screws are made from spheroidal cast ironand their design has changed little over the years.OCAMICA Hnos, the company manufacturing the lockscrew, is collaborating with TECNALIA to develop a newproduct with the sole limitation of the minimum resistanceit has to withstand. This product is widely used inconstruction, workshops, etc.SolutionAfter validation on the OCAMICA test benches, the productwas presented at several international trade fairs withsatisfactory results, allowing the client to penetrate newmarkets.All the production is currently sent to France, the UnitedKingdom, Ireland, Norway, etc.
    21. 21. REFERENCES for the Foundry INDUSTRY 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. Internal and external refrigeration Infrared measurement Intelligent control Calculated output of 700 refrigeration times 600 500 400 Serie1 Tª Serie2 300Thermocouple 200 T Inputs PLC 100measurement 0 0 4 3 7 2 6 0 5 9 3 2 6 5 9 4 8 8 8 1 8:5 8:5 8:5 9:0 9:0 9:1 9:1 9:2 9:2 9:2 9:3 9:3 9:4 9:4 9:5 9:5 9:5 0:0 0:0 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:4 9:5 9:5 Hora
    22. 22. REFERENCES for the Foundry INDUSTRY CASTPRESS: 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. SeeVideo
    23. 23. REFERENCES for the Foundry INDUSTRY CASTING of LIGHT MATERIALS: Aluminium and Mg Target Weight Reduction and High PerformanceTechnologyALUMINIUM: Gravity Casting,Investment/Lost Wax Casting , Lost Foam(Sand / Magnetic moulding - Steel Shots),HPDC, Squeeze Casting, Plaster CastingMAGNESIUM: Gravity, Investment / lostwax, Lost Foam (Sand), HPDC (ProjectsStarting December 2008)Application sALUMINIUM: Know-Products: Brake disk, Piston, Cylinder Head, HowCallyper Material development, characterizationMAGNESIUM: and process(Projects Starting December 2008)Products: Seat Frame, Steering Wheel,Instrument panel carrier 2
    24. 24. REFERENCES for the Foundry INDUSTRY CASTING: Al-MMCs (Aluminium Matrix Composites)NeedManufacturing prototypes of an automotive component(brake drum) in a composite material and the finetuning of the different forming technologies: gravitymetal mould casting, sand mould casting and SqueezeCasting.These composites are known for their high wearresistance, excellent mechanical properties at averagein-service temperatures and their heat conductivity.Solution Brake drum (Courtesy of Fagor Ederlan)Comparison of the results of the metal mould and sandmould techniques shows the former to be best: asmaller grain size is achieved, as well as reducedporosity, giving improved mechanical properties thatcan be improved by subsequent heat treatment.Specific industrial applications for automotivecomponents: brake discs and drums, clutch discs, Squeeze Casting Processcylinders and pistons.
    25. 25. REFERENCES for the Foundry INDUSTRY CASTING: Al-MMCs (Aluminium Matrix Composites)Material:Al/TiB2 composites produced by “in situ”methodsImprovements:Wear, Low CTE, lightness and mechanicalproperties at high temperaturesAplications:Clutch discs, pistons and railway brake discs 2
    26. 26. REFERENCES for the Foundry INDUSTRY CASTING: Al-MMCs (Aluminium Matrix Composites)Material:Al/Al2O3 and Al/SiCp CompositesImprovements:Wear, Lightness, Low CTE and MechanicalProperties at high temperatures LOCAL REINFORCEMENTAplications:Clutch discs and ventilated brake discs
    27. 27. REFERENCES for the Foundry INDUSTRY Chemical Conversion CoatingsChromium free conversion coatingPatents: 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 hours 2
    28. 28. REFERENCES for the Foundry INDUSTRY Anodising 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 Nanoparticles top layer: 150nmAnodic oxide layer: 2.7 microns TEM cross section 2
    29. 29. REFERENCES for the Foundry INDUSTRY Thermal Spraying : Development of technology & equipment (3 of 3) SeeVideo Protection of Al moulds with wear & corrosion resistant coatings 3
    30. 30. REFERENCES for the Foundry INDUSTRY Permanent wear resistant coatings for die casting and low pressure injection molding of Al parts (I)Development of permanent or semi-permanentcoatings produced by PVD (Physical VapourDeposition), with a wear life significantly higher (min.x 4-6 times) than traditional demoulding agents andavoiding or minimising their problems.Work consisted on:•Study on compatible coatings with die casting moldsand dies able to improve performance of actualsolutions.•Optimizing PVD processes for the present industrialapplication.•Establishment of procedures for its application onmoulds.•Industrials tests with the new coatings.•Cuantify the improvement and define possibleapplications. Coquilleuse équipée de deux outillages.•These coatings shall improve availability and Outillage revêtu du dépôt Outillage revêtu de poteyagesproductivity of moulds. PVD - CrAlN conventionnels.
    31. 31. REFERENCES for the Foundry INDUSTRY 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.
    32. 32. Solid lubricant coatings on Al parts (by PVD Technology) 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  reduced emisions (from 1,5 to 0,3% oil reduction 15% reduction in hidrocarbons, 10% in CO, 10% in visible smoke)• Solid lubrication in contacting surfaces to counteract loss of liquid lubrication.• Hard wear resistant coating + outer solid lubricant, to extend wear life. 3
    33. 33. REFERENCES for the Foundry INDUSTRYExample:Production of Al powder from Al/plastic film wasteAluminium / 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: withAl coated plastic film waste a calorific value of 7000 kcal/m2 (lower than natural gas 9000 kcal/m2)Successful industrial trials carried out with: exothermic sleeves & Al tablets 3