Driving disruptive metal castings sector technology innovations by sustainability requirements: A general methodological approach and two cases

1. Driving disruptive metal castings sector
technology innovations by sustainability
requirements:
A general methodological approach and
two cases
Raul Carlsson
1
Research engineer, raul.carlsson@swerea.se
raul.carlsson@ri.se (from 1st of October 2018)
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

2. Contents
• Swerea and RISE
• Cast metal sustainability challenges
• How we did
• What we did
• A general method to copy us
2
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

3. Swerea, from 1:st of October 2018 a research
division within RISE
RISE
• Swedish governmentally owned
research institute
• Around 2300 employees
• RISE is 100% owner of Swerea
since 1 July 2018
• Merging of Swerea into RISE
will be finalized during October
2018
3
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

4. 4
Cast metal components
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

5. CAST COMPONENTS IN A RECYCLING ECONOMY
K. REUSE METAL
I. LOSS
2. BASE
METAL
INDUSTRY
0. MINING
1. QUARRY
4. SECONDARY
USE
9. SERVICE
11. ROUGH
SCRAP
FRACTION
LOGISTICS
7. DIS-
ASSEMBLY
6. USE
5. POST
PROCESSING
3.
CASTING
I. Waste
mgmt
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

6. 0
Metal value life cycle
Metalvalue
Mining
Rawmaterial
Component
Product
Scrap
Recycling
Loss
Exploration
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

7. Sustainability challenges
• Generic
• Depletion of non-renewable resources
• Emissions
• Climate impact
• One idea:
• Turn cast metal components circular
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

8. Källa: http://www.ellenmacarthurfoundation.org/circular-economy/interactive-diagram 2015-11-24
Circular economy

9. CAST COMPONENTS IN A CIRCULAR ECONOMY
H. REUSE COMPONENT
J. REUSE ALLOY
K. REUSE METAL
I. LOSS
2. BASE
METAL
INDUSTRY
0. MINING
1. QUARRY
4. SECONDARY
USE
9. SERVICE
G. REUSE COMPONENT
10. PURE
SCRAP
FRACTION
LOGISTICS
11. ROUGH
SCRAP
FRACTION
LOGISTICS
8. USED
COMPONENT
MGMT
7. DIS-
ASSEMBLY
6. USE
5. POST
PROCESSING
3.
CASTING
I. Waste
mgmt
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germanyg 29-31 August 2018

10. Circular cast metal components
• The idea:
• Turn cast metal components circular
• The general plot:
• Traceability
• Reverse logitistics
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

11. Industry response
• Traceability
• Why?
• No.
• We do what customers want.
• Hard or very costly at individual level.
• Generally expensive
• Not very useful
• Material recycling is already very good, above 90%
• Alloy purity is no problem
• etc.
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

12. • Traceability
• Why?
• No.
• We do what customers want.
• Hard or very costly at individual level.
• Generally expensive
• Not very useful
• Material recycling is already very good, above 90%
• Alloy purity is no problem
• etc.
Aha Very motivational!
• Traceability
• Why? – This question calls for an answer!
• No. – This response is a temporary statement
• We do what customers want. – Thanks for the idea!
• Hard or very costly at individual level. – A technical specification
• Generally expensive – An economic boundary
• Not very useful – We need to identify more applications
• Material recycling is already very good, above 90% - old timers
• Alloy purity is no problem – in a sustainabiity perspective it is
• etc. – come back with something extraordinary!
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

13. So we listened
• The industry is very cost and quality driven
• Traceability may be of valuable for
production quality analysis
• Game changers may be welcome, to
elevate revenue in the industry
• Customer drive may enable win-wins
throughout cast metal component and alloy
life cycle
13
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

14. Idea: brave transformative innovations
• Digitized metal
• For traceabiltity
• For smart castings
14
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

15. Traceability
Identity:
• Manufacturer
• Article number
• Serial number
Technical specifications
Geographical scan log
Cast metal components with digital tag
Production data
Quality check log
A Swerea
smart materials
demonstration project
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

16. Källa: http://www.ellenmacarthurfoundation.org/circular-economy/interactive-diagram 2015-11-24
Identity:
• Manufacturer
• Article number
• Serial number
Production data
Quality check log
Position
Calendar data
may serve to facilitate recycling, refurbishment,
remanufacturing, reuse and redistribution, and to
share products and components.
Traceability
Cast metal components with digital tag

17. 0
Metalvalue
Mining
Rawmaterial
Component
Product
Scrap
Recycling
Loss
Exploration
Mining
Rawmaterial
Component
Product
Scrap
Recycling
Loss
Exploration
Mining
Rawmaterial
Component
Product
Scrap
Recycling
Loss
Exploration
Maintaining a higher value
through several use cycle loops
Traceability
Metal value life cycle, with reuse
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

18. 18
Cast metal components with integrated sensors
A Vinnova spearhead project
Win-win, higher value and higher revenue
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

19. 19
Cast metal components with integrated sensors
Enable innovative
services:
• Status monitoring
IT is OK.
• Service optimization
IT is still OK.
No service needed.
• Machine control
Too much torque.
Please turn the
effect down a bit.
• Resource
efficient
constructions
It is OK, but please
be aware you are
close to my narrow
marginals.
• And many more
innovative services
Is there anything
else I can do for
you?
Win-win, higher value and higher revenue
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

20. Källa: http://www.ellenmacarthurfoundation.org/circular-economy/interactive-diagram 2015-11-24
Services
• Status monitoring
• Service optimization
• Machine control
• Resource efficient constructions
• And many more innovative services
may serve to maintain and prolong lifetime.
Cast metal components with integrated sensors
Win-win, higher value and higher revenue

21. 0
Metalvalue
Mining
Rawmaterial
Component
Product
Scrap
Recycling
Loss
Exploration
Mining
Rawmaterial
Component
Product
Scrap
Exploration
Added ’smartness’
functionality adds
value and maintains
high value by
facilitating service
Mining
Rawmaterial
Component
Product
Scrap
Exploration
Win-win, higher value and higher revenue
Metal value life cycle, with added functionality
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

22. CAST COMPONENTS IN A CIRCULAR ECONOMY
H. REUSE COMPONENT
J. REUSE ALLOY
K. REUSE METAL
I. LOSS
2. BASE
METAL
INDUSTRY
0. MINING
1. QUARRY
4. SECONDARY
USE
9. SERVICE
G. REUSE COMPONENT
10. PURE
SCRAP
FRACTION
LOGISTICS
11. ROUGH
SCRAP
FRACTION
LOGISTICS
8. USED
COMPONENT
MGMT
7. DIS-
ASSEMBLY
6. USE
5. POST
PROCESSING
3.
CASTING
I. Waste
mgmt
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

23. 0
Smart metal value life cycle
enabling higher value material loops
Metalvalue
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

24. Result
• Traceability enables a closed loop win-win-chain
• We now talk technical development and business cases
• We have sustainability requirements on the technical solutions
• Business and innovations is now the driver of change
• Smart castings enables revenue
• The innovation is the driver of revenue which enables change:
• Positive feedback
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

25. General method
1. Identify core sustainability challenge of a business
2. Make a wish: What should it look like in Utopia
3. Design core elements of Utopia
4. Turn the core elements into business advantages for
your industry
5. Demonstrate
6. Keep focus: Innovate for revenue and win-win-loops
7. Establish innovation eco-systems
8. Keep it up
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

26. The takeaway
• Know the sustainability challenges
• Turn the challenges into internalized opportunities
for your business
• Aim at high revenue and circular win-win closed
loops
26
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018

27. 27
Scientific Work for Industrial Use
www.swerea.se
Contact: raul.carlsson@swerea.se
From 1:st of October 2018:
raul.carlsson@ri.se
Thank you for listening!
Copyright R. Carlsson, Presented at LCIC 2018, Berlin, Germany 29-31 August 2018