Objectif In the project period the following outputs were achieved:* Material properties and specification for the automotive and aeronautical applications.* Material selection. * Ingots of selected material.* Detailed characterization of alloys * Selected components and its specifications.* Detailed simulation tests.* Design of laboratory experiments/preliminary laboratory results.* Laboratory experiments data for the numerical model implementation.* Implemented numerical model.* Production of pure PMMA L-F patterns.* Production of crankshaft and rib castings.* Introduction of cast-in oil channels.* Fill monitoring of the state-of-the-art casting clusters.* Environmental investigation of the L-F pattern degradation products.* Cost benefit analysis.* Mechanical and micro-structural characterisation.Objectives and content The overall object of this project is to develop an innovative casting technology for manufacture near net shape steel components, compatible with the mass production requirements of transport industry. The proposed approach for reaching this target, is to advance the Lost Foam technology for its application to steel. Lost Foam technology can be considered to be satisfactorily developed for aluminium alloys and cast iron, becoming more and more widespread due to its advantages in comparison with other technologies. The possible extension of Lost Foam casting to steel grades represents a great technological innovation and a very attractive industrial goal due to the following reasons. At present time the most widespread forming processes for steel are stamping for sheets and forging for massive parts; the steel casting technologies, till now available, are not diffused in the transport industry mainly because they are not cost competitive and/or not compatible with mass production. From the technological point of view, the development of Lost Foam technology for steel casting will lead to technical, economical and environmental benefits: near net shape forming, high casting quality, low tools investment, high productivity, high process energy efficiency, reduction of pollution and cast part cleaning operations for better working conditions. From the transport industry point of view, there is a very strong need of innovative technologies for the traditional materials to remain competitive. Several research programs (i.e. PNGV, ULSAB) are demonstrating the wide range of improvement by ferrous materials technologies in terms of component performances (i.e. weight reduction for environmental benefit, improved structural behaviour) as well as production costs saving. The technical approach proposed will consist of the following main tasks: material selection (steel grades) as function of process and components requirements, - process numerical simulation, process development by laboratory and pilot plant experiments, industrial applications selection, design, manufacture and testing; cost/benefit evaluation. The main expected deliverables of the project are the following: Lost Foam casting procedure for steel parts two different automotive components one aeronautical components economical benefits evaluation on real parts. The planned activities are structured for complementary competencies (automotive, aeronautical, SME industries) through quality methodologies in concurrent engineering, design for process capabilities and simultaneous cost analysis. Champ scientifique natural scienceschemical sciencesinorganic chemistrypost-transition metalssocial scienceseconomics and businesseconomicsproduction economicsproductivitynatural sciencesearth and related environmental sciencesenvironmental sciencespollution Programme(s) FP4-BRITE/EURAM 3 - Specific research and technological development programme in the field of industrial and materials technologies, 1994-1998 Thème(s) 0201 - Materials engineering Appel à propositions Data not available Régime de financement CSC - Cost-sharing contracts Coordinateur CENTRO RICERCHE FIAT S.C.P.A. 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