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Robust, and FLEXible CAST iron manufacturing

Objective

The FLEXICAST project presents knowledge-based technologies that aim to follow the way to transform the conventional (batch-by-batch) foundry process into a flexible (mold-by-mold) process. The proposal technologies will be applicable not only to new cast iron foundry lines, but also is readily available to be retro-fitted to existing plants. The specific objectives are:a)A cast iron production cell. Together with melting, treatment and pouring sub processes in a cast iron production cell is essential and imperative. We propose to install the melting shop closer to the pouring system kept closed on the mould carrousel, while the transfer and treatment ladle is removed. The widespread adoption of new melting shop as an operating process is in itself fostering the creation of even more powerful induction-plasma power supplies, versatile melt control technology, high-power density furnaces, temperature control systems, nodularization systems(magnesium vapour), inoculation systems, and automated pouring systems.b)Integration of Artificial Intelligence-based Control System. The objective is to develop a software platform. This can help us to the prediction of local structures, phases and ultimately the local mechanical properties, to asses casting quality in the foundry. In this point, also, three specific methodologies will be studied and improved:DTA analysis and on-line microstructural analysis and X-ray for on-line inspection.c)A robot cell for automated metal finishing processes. d)Demo pilot plant in real industrial settings in order to demonstrate a clear breakthrough using project development in comparison with the state-of-art solutions. Some results are:a)Cast iron manufacturing cell represents, at least, 30% energy reduction in comparison with conventional melting systems.b)Drastic reduction melt temperature scattering during molding process. Reduce metal transport (No transfer and treatment ladles).c)Overheating reduction.d)Reduce rejection of casting pieces

Field of science

  • /natural sciences/chemical sciences/inorganic chemistry/inorganic compounds
  • /natural sciences/computer and information sciences/software
  • /social sciences/social and economic geography/transport

Call for proposal

FP7-2012-NMP-ICT-FoF
See other projects for this call

Funding Scheme

CP-TP - Collaborative Project targeted to a special group (such as SMEs)

Coordinator

UNIVERSITAT POLITECNICA DE CATALUNYA
Address
Calle Jordi Girona 31
08034 Barcelona
Spain
Activity type
Higher or Secondary Education Establishments
EU contribution
€ 925 700
Administrative Contact
Valenti Guasch (Mr.)

Participants (15)

FUNDACIO PRIVADA ASCAMM

Participation ended

Spain
Address
Avenida Universitat Autonoma , Parc Tecnologic Del Valles 23
08290 Cerdanyola Del Valles
Activity type
Research Organisations
Administrative Contact
Joan Guasch (Mr.)
FUNDICIONES DE RODA S.A.
Spain
EU contribution
€ 812 524
Address
Carrer Disseminats
08510 Roda De Ter
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Pedro Cabani (Mr.)
PROSERVICE SRL
Italy
EU contribution
€ 402 800
Address
Via Marco Polo 3
35010 Borgoricco
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Nicola Segreto (Mr.)
ONDARLAN S L
Spain
EU contribution
€ 487 600
Address
Poligono Txirrita Maleo 10
20100 Renteria Gipuzkoa
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Manuel Castro (Mr.)
FUNDACION TECNALIA RESEARCH & INNOVATION
Spain
EU contribution
€ 544 300
Address
Parque Cientifico Y Tecnologico De Gipuzkoa Paseo Mikeletegi 2
20009 Donostia/san Sebastian (Gipuzkoa)
Activity type
Research Organisations
Administrative Contact
Ane Irazusta Barrena (Ms.)
SERT-METAL SAS

Participation ended

France
Address
Avenue De L'europe 3
69150 Decines Charpieu
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Patrick Simonnin (Mr.)
FUNDACIO EURECAT
Spain
EU contribution
€ 194 633,80
Address
Avenida Universitat Autonoma 23
08290 Cerdanyola Del Valles (Barcelona)
Activity type
Research Organisations
Administrative Contact
Joan Guasch (Mr.)
CONSIGLIO NAZIONALE DELLE RICERCHE
Italy
EU contribution
€ 536 634,50
Address
Piazzale Aldo Moro 7
00185 Roma
Activity type
Research Organisations
Administrative Contact
Lorenzo Molinari Tosatti (Dr.)
COMAU SPA
Italy
EU contribution
€ 314 521,90
Address
Via Rivalta 30
10095 Grugliasco
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Fulvio Rusinà (Mr.)
CENTRE INTERNACIONAL DE METODES NUMERICS EN ENGINYERIA
Spain
EU contribution
€ 460 836
Address
C Gran Capitan, Edifici C1, Campus Nord Upc Sn
08034 Barcelona
Activity type
Research Organisations
Administrative Contact
Sandra Pérez (Ms.)
TRELLEBORG SEALING SOLUTIONS ITALIA SPA
Italy
EU contribution
€ 178 453
Address
Via G. March 11
57121 Livorno
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Carlo Calvietti (Mr.)
INNOSPEXION APS
Denmark
EU contribution
€ 320 000
Address
Horseager 14
4330 Hvalso
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Joergen Rheinlaender (Mr.)
POLITECHNIKA POZNANSKA
Poland
EU contribution
€ 252 199,60
Address
Pl Marii Sklodowskiej Curie 5
60 965 Poznan
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Aleksandra Rakowska (Prof.)
ARC SRL
Italy
EU contribution
€ 150 900
Address
Via Vittorio Botego 36-38
41126 Modena
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Trebbi Marcello (Dr.)
FOSECO FRANCE SAS
France
EU contribution
€ 118 897,20
Address
7 Mail Barthelemy Thimonnier Le Newton
77185 Lognes
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Isabelle Blouse (Ms.)