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Improving casting quality and reducing lead times by integration of solidification simulation and real time imaging of metal flow

Objective



SME foundries particularly those making low volumes of high value castings see an opportunity to significantly reduce lead times and prototyping costs while at the same time improving casting quality if the accuracy and reliability of solidification modelling could be improved. Solidification modelling although widely available has not been accepted by SME's to the extent expected. The specific objective of this Project is to integrate solidification modelling with real time monitoring of metal flow into mould cavities using high energy radiography and exaniining cast sections representative of those used in practice which was not previously feasible. This will enable the cause of defects to be identified at source and casting quality to be predicted at the design stage. Quantitative verification on test castings will enable best practices to be established and disseminated throughout Europe to the benefit of SME producers and t'ne diverse engineering industries which are dependent on cast components. Guaranteeing quality at the design stage is expected to reduce lead times by at least 50%, save at least 130m ECU in scrapped castings, and lead to new markets and an increased market share for castings. Benefits will accrue from the links established between casting producers and users.

Funding Scheme

EAW - Exploratory awards

Coordinator

VANGUARD FOUNDRY LTD.
Address
Bott Lane
DY9 7AN Stourbridge
United Kingdom