European Funds drive industry
We have obtained funding from the European Union under the European Funds for a Modern Economy programme for the implementation of the project entitled:
“Design and material conversion of ingot moulds for ferroalloy (FeSiCr) casting in order to increase their service life and significantly reduce material consumption rates.”
Project number: | FENG.01.01-IP.02-0696/23 |
| Programme: | European Funds for a Modern Economy |
| Priority: | Support for Enterprises |
| Measure: | FENG.01 .01 SMART pathaway |
The project is being implemented within a consortium together with the AGH University of Science and Technology – Faculty of Foundry Engineering research unit.
Project Objective:
Research issues to be addressed:
Research work at this stage is conducted by the AGH University of Science and Technology – Faculty of Foundry Engineering. Laboratory-scale research is being carried out on specially manufactured ingot mould models and moulds at a 1:10 scale, while maintaining the original shape and thickness proportions.
The activities include:
- Development of technology for producing the top layer of ingot moulds through alloy modification using active coatings applied to the mould surface.
- Evaluation of the microstructure of cast iron used for FeSiCr ingot moulds, conducting directional solidification studies, and developing technology to ensure a controlled structure characterized by the absence of macro-porosity in selected walls of FeSiCr ingot moulds.
- Simulation of structure formation in thick-walled ingot mould castings for FeSiCr ferroalloy casting and optimization of the ingot mould casting design.
- Analysis of ingot mould performance under combined thermal and stress conditions, identification of critical thermal shock zones, and development of methods to reduce thermal stress levels.
- Development of technology for producing ceramic–metallic surface layers in experimental castings and ingot moulds for FeSiCr alloy casting.
- Testing of thermophysical and resistance properties of the produced layers.
INDUSTRIAL RESEARCH ON INGOT MOULD DESIGN AND GEOMETRY, AND ON THE TECHNOLOGY FOR APPLYING CERAMIC–METALLIC SURFACE LAYERS
The activities carried out include:
Measurement of baseline operational and service data of the ingot mould at the user’s facility in order to obtain input data for computer simulations of the pouring process and ingot mould performance using Magma and NX-type software.
Development of technological assumptions regarding design modifications of the ingot mould.
Preparation of technological documentation, including: foundry mould documentation, moulding equipment (boxes, patterns), casting acceptance documentation, surface roughness specifications, casting defect class, development of required casting inspection procedures, and design of a station for applying active coatings.
Development of metal technology.
Gradient structure testing on thick walls, trepanning tests on casting cross-sections; microstructure analysis using an optical microscope; mechanical strength testing using a universal testing machine; non-destructive ultrasonic testing; and thermal conductivity testing.
Metallographic and mechanical testing, as well as testing of physical properties.
Gradient structure testing at the bottom of the ingot mould, trepanning tests on casting cross-sections; microstructure analysis using an optical microscope; mechanical strength testing using a universal testing machine; non-destructive ultrasonic testing; and thermal conductivity testing.
Simulations performed using Magma and NX-type software.
According to the R&D work plan, the final stage involves experimental development work aimed at demonstrating, testing, and validating the new products under real operational conditions.
The activities include:
Production of prototype castings.
Non-destructive and destructive testing on both assembled and separately cast samples.
Installation of recorders to monitor ingot mould operating conditions.
Examination of the mould: assessment of the degree and uniformity of sand compaction using trepanning and ultrasonic methods, and testing the properties of mould coatings.
Trepanning tests on castings: analysis of structure and mechanical properties, hardness (strength) testing, material testing, and chemical composition analysis on trial, pilot, and prototype series.
Computer simulations: analysis of heat flow, crystallization processes, microstructure formation, and thermo-mechanical changes occurring in the casting.
Validation of the developed technological assumptions under real operational conditions.
Project Effects / Results
As a result of the R&D work, it will be possible to manufacture ingot moulds with:
Significantly improved performance parameters, allowing for an increase in mould service life by at least 30% and a reduction in the material consumption rate required to produce one ton of ferroalloy from 17 kg to 14.2 kg/Mg.
Modified design due to the use of cast iron with compacted graphite. The mould will feature a reinforced working layer at the bottom, which will reduce overheating and thermal stresses—the main causes of cracking.
Extended service life, enabling longer operational periods in ferroalloy foundries, longer mould campaigns, and delivering significant economic, logistical, and environmental benefits.
Target Groups
The target market includes the automotive, aerospace, construction, machinery, metallurgical, and energy industries. These sectors use ferroalloy castings for the production of various components, machine parts, automotive parts, structural elements, tools, and infrastructure-related components.
The innovativeness of the new products will attract companies requiring durable, high-temperature-resistant castings. Thanks to the additional ceramic–metallic layer, the ingot moulds will be more durable and resistant to erosion, corrosion, and high temperatures—an essential feature for the production of components exposed to extreme operating conditions.
The project is co-financed by the European Union under the European Funds for a Modern Economy program.
Project value: 10 525 970,70 PLN
Funding amount: 7 147 286,25 PLN
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