-Development of high density and high strength graphite materials to improve casting product quality and to increase lifetime of dies.
-Determination, recording and optimization of the decisive process parameters.
-Computer aided development of process control systems.
-Catalytical effects of the alloy and their impurities between the liquid/solid metal surface and the surface of the die graphites are tested.
-Reaching of the production start of bronze strips without surface defects on the micrometre level as an improved material for new electric connectors compared with conventional brass materials.
The achievements can be summarised as follows:
operative tests of present and competitive die graphites lead to comparable lifetimes of the dies and defect concentrations of the strips;
an advanced graphite material with high density, high strength, high thermal conductivity and high notch value was developed;
recording and determination of the decisive process parameters was performed whereby the present graphite gives a lower pressure level than the competitive graphite;
computer aided development of process control systems was started by recording force profiles.
Laboratory casting tests resulted in higher casting speed and good surface quality of the cast strips by using the advanced graphite. Unfortunately a second advanced graphite showed a porous surface after machining the die.
This work should result in improving the casting conditions in the European nonferrous casting industry.