European Funds drive industry
We have received funding from the European Union under the European Funds for a Modern Economy program for the implementation of the project titled:
„Development of an innovative technology for manufacturing counterweights using a novel membrane-based method for mass densification, assembly of positioning elements, and 3S framework boxes enabling control of the crystallization and cooling process of the casting.”
Project number: | FENG.01.01-IP.02-0696/23 |
| Programme: | European Funds for a Modern Economy |
| Priority: | Support for Enterprises |
| Measure: | SMART pathaway |
Project Objective:
The objective of the project is to develop an innovative manufacturing technology for significantly improved dome and flat ballast weights, as well as to design a completely new system for positioning and stabilizing the component elements of tower ballasts through controlled crystallization and cooling of the casting process, in order to increase their dimensional and geometric accuracy. During the research work, the following will be carried out: – development of a new system of moulding boxes, referred to as skeletal 3S moulds, together with a digital LCA module, which will reduce the time required for casting solidification and cooling by approximately 30%, while also improving casting geometry.
During the research work, the following will be carried out:
development of a new system of moulding boxes, referred to as skeletal 3S moulds, together with a digital LCA module, which will reduce the time required for casting solidification and cooling by approximately 30%, while also improving casting geometry.
A novel method of moulding sand compaction will be developed, enabling uniform densification of the moulding material (increasing mould rigidity and reducing casting deformation).
Research issues to be addressed:
Stage 1 COMPLETED on 30.11.2024
Industrial research on the development of an innovative method and membrane-based device for the vibratory compaction of large moulds.
- The concept for the division of the modular ladle casting was developed.
- The design of the modular casting was completed, along with the necessary thermal load simulations, as well as static and fatigue analyses.
- An effective method for ladle sealing and leak-tightness control was developed.
Stage 2 COMPLETED on 31.01.2026
Industrial research on 3S moulding box technology and control of the crystallization and solidification process.
- The technology for moulds and moulding sands dedicated to accelerated mould cooling was developed.
- Research was conducted and self-hardening moulding and core sands were selected, along with their technological parameters.
- Protective coatings for moulds and cores, as well as auxiliary materials for mould and core production, were selected.
- Guidelines were prepared for the production of pattern equipment and foundry tooling for dome and flat ballast weights.
2. Metal technology was developed.
- The pouring and secondary metallurgy processes were developed: appropriate materials for the secondary treatment of molten metal were selected, and the treatment temperature and time from treatment to the completion of pouring were determined.
3. Knockout, cleaning and finishing technologies were developed.
4. Prototype moulding boxes in the 3S system were developed and manufactured.
- Simulations of casting cooling and crystallization were carried out.
Stage 3 IN PROGRESS
Industrial research – Ballast positioning systems:
- foundry-based – embedded in the casting
- mechanical – bonded mounting feet
- Simulations of stresses, strains and displacements of castings carried out using Simcenter3D (NX Nastran) software.
- Simulations of casting pouring and solidification times carried out (Magma).
- 3D scanning of castings with fastening elements performed.
- Linear measurements carried out using a 3D scanner and contact probes.
- Surface roughness and flatness measurements performed using a prototype laser profilometer.
- Strength testing of the joints between the insert and the casting conducted.
Stage 4 IN PROGRESS
Experimental development work – Validation of the technology confirmed through analytical and laboratory research.
The final stage of the project involves experimental development work aimed at demonstrating, testing, and validating new solutions under real-world conditions.
The developed technology and its effects, in the form of a higher-quality and more precise product, undergo thorough analysis on the final products produced using the innovative technology.
This allows the qualified R&D team to verify the assumptions made at the initial stage of technology design.
Project Effects / Results
The implementation of the project will enable the offer of a significantly improved product with enhanced quality and increased dimensional and geometric accuracy, greatly reducing the need for mechanical processing.
The new system for positioning and stabilizing the component elements of tower ballasts will allow replacement of cast positioning elements with precise components made from high-strength rolled steel. The developed innovative ballast connection system will eliminate displacement, detachment, or misalignment of ballasts. These are key aspects related to the safety of personnel performing construction and earthworks.
The project will also result in:
Process innovations:
– 3S skeletal moulding box system
– Membrane-based sand mould compaction
– Tower ballast positioning and stabilization system
– Embedded fastening and transport elements system
Product innovations:
– Dome ballasts
– Flat ballasts
Target Groups
The primary target market includes the metallurgical industry and the construction machinery sector. Castings with increased strength and manufacturing precision will also find applications in the production of structural components for buildings, bridges, and other infrastructure projects that require high durability and reliability. These products are also important for the mining industry, particularly in the production of components for equipment used in oil and gas exploration, drilling, and extraction. The innovativeness of the new products will help create new markets in which Krakodlew S.A. has not previously participated, such as the nuclear industry, which also requires heavy, massive machines and equipment characterized by the highest precision, technology, and safety standards.
The project is co-financed by the European Union under the European Funds for a Modern Economy program.
Project value: 9,403,598.13 PLN
Funding amount: 5,924,559.21 PLN
#EUFunds #EuropeanFunds
