Url https://www.cimne.com/sgp/rtd/Project.aspx?id=584
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Project title Robust, and FLEXible CAST iron manufacturing
Official Website http://flexicast-euproject.com/
Reference 314540
Principal investigator Eugenio OÑATE IBAÑEZ DE NAVARRA - onate@cimne.upc.edu
Start date 01/11/2012 End date 31/10/2016
Coordinator UPC
Consortium members
  • Univ. POZNAN
  • ARC
  • SERT
Program FP7 (2007-2013) Call FP7-2012-NMP-ICT-FoF
Subprogram COOPERATION Category Europeo
Funding body(ies) EC Grant 460.836,00 €
Abstract 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. Overheating not only wastes energy but can damage the lining of the furnace and can cause quality problems. d) Reduce rejection of castings pieces, but most important, major cost savings in charge metal, treatment and refractory costs.