innovative hot chamber Medium Pressure Die Casting process for Aluminium

Informazioni relative al progetto

MPDCA

ID dell’accordo di sovvenzione: 808257

DOI

10.3030/808257

Progetto chiuso

Data della firma CE 22 Marzo 2018

Data di avvio 1 Aprile 2018

Data di completamento 31 Agosto 2018

Finanziato da

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies – Nanotechnologies

Costo totale

€ 71 429,00

Contributo UE

€ 50 000,00

Coordinato da

NEWMEC SRL
Italy

Periodic Reporting for period 1 - MPDCA (innovative hot chamber Medium Pressure Die Casting process for Aluminium)

Periodo di rendicontazione: 2018-04-01 al 2018-08-31

Sintesi del contesto e degli obiettivi generali del progetto

"The hot-chamber process is used for die-casting of light alloys due to its clear advantages over the cold-chamber one: smaller installations, lower pressures, more controlled temperature, better quality, less scrap, lower energy consumption, etc. Despite these benefits, the hot-chamber system cannot be used for aluminium die-casting because the molten aluminium attacks the metallic parts of the injection pump and the die-casting machine.
If the hot chamber process could be used for aluminium, the quality of the components would be higher and their cost significantly lower. A lot of energy would be saved too.
#MPDCA project is aimed to put in the market a disruptive technology based in the development of a new injection pump that enables the fabrication of hot-chamber machines for aluminium die casting.
"

Lavoro eseguito dall’inizio del progetto fino alla fine del periodo coperto dalla relazione e principali risultati finora ottenuti

During the technical feasibility study, we have assessed the required specifications for the injection pump (body, piston and sealing) and the cavity filling with MPDC process, evaluating temperatures and pressures. We have also performed a materials and cost evaluation, and analysed the technical risk for industrialization.
MPDCA will be the only system in the market for hot-chamber die-casting of aluminium. It enables for better quality, lower operation costs and less energy consumption. The business opportunity is clear because the demand of aluminium die-cast strongly rising, mainly driven by automotive industry. The target market are the die-casters that supply to automotive and transport sectors and also the OEMs (as prescribers). We have analysed the competitors and the potential partners, as well as the IP protection (the technology is patented).
From the financial point of view, we have considered the risks and market barriers and made a SWOT analysis. The revenues will come from new machines, retrofitting of old machines (cold-chamber) and licensing of technology. The expected ROI after 5 years is 4.4 and the new staff recruitment >200

Progressi oltre lo stato dell’arte e potenziale impatto previsto (incluso l’impatto socioeconomico e le implicazioni sociali più ampie del progetto fino ad ora)

Nowadays, aluminium die-casting can also be done with cold-chamber machines. Some attempts to use the most advantageous hot-chamber process performed during the last decades have failed, but we have developed an injection pump that can be used to build hot-chamber machines for aluminium die-casting. It is a disruptive development for the aluminium die-casting sector that will make the present technology obsolete.
The new process enables to use smaller installations and to produce better components at lower cost. The energy consumption will drop more than 25%. It will be possible to retrofit the present installations to adapt them to the new technology.
The creation of a bigger consortium to take this technology to the market is being considered.

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