Objective
The Lost Foam Casting is a quite new casting technology, which provides many different technical, economical and environmental advantages. However, in casting of aluminium alloys, this process makes a lot of problems, and rejection rates of up to 20 % are usual. Thus, although the technique has some advantages, its present market share is unsatisfactory compared to other casting technologies. Most of the problems are due to insufficient properties of the Lost Foam Coating, which is put onto the plastic pattern in the liquid state and after drying insulates the molten metal from the form sand. The key properties of such a coating are a definite permeability for the molten and gaseous decomposition products of the foam and at the same time a high mechanical stability. Additionally other properties, which can enable easy handling prior to casting, and easy and complete removal after casting, are essentially. The necessary properties are difficult to be achieved with conventional coatings for the conditions of aluminium casting. In this project a new type of Lost Foam Coating for casting of aluminium alloys will be developed and tested. The new approach to the chemical composition of the coating consists in adding reactive components, which can provide a chemical reaction at the casting temperature or below and form a porous ceramic layer with the desired superior properties. To do these developments, a consortium of industrial suppliers and producers of coatings and of casting factories for testing the products as end users has been established (SME), while the scientific work necessary is done by RTD performers. It is expected, that by the use of the new coating the rejection rate of the process can be reduced from 20 % to 1 %, so that in perspective the market share of lost foam aluminium casting may be drastically raised . Successful completion of the envisaged research project will therefore improve the competitive situation of medium sized aluminium casting companies in Europe which are suppliers for example to the automotive industry.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
- engineering and technologymechanical engineeringvehicle engineeringautomotive engineering
- natural scienceschemical sciencesinorganic chemistrypost-transition metals
- engineering and technologymaterials engineeringcoating and films
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Topic(s)
Call for proposal
Data not availableFunding Scheme
CRS - Cooperative research contractsCoordinator
53773 Hennef
Germany