SOUNDCAST

Vacuum-assisted high pressure die castings with reduced porosity at low cost

 Coordinatore CASA MARISTAS AZTERLAN 

 Organization address address: ALIENDALDE AUZUNEA 6
city: DURANGO
postcode: 48200

contact info
Titolo: Mrs.
Nome: Ana
Cognome: Fernandez
Email: send email
Telefono: +34 94 6215470

 Nazionalità Coordinatore Spain [ES]
 Totale costo 1˙747˙861 €
 EC contributo 1˙114˙999 €
 Programma FP7-SME
Specific Programme "Capacities": Research for the benefit of SMEs
 Code Call FP7-SME-2012
 Funding Scheme BSG-SME
 Anno di inizio 2012
 Periodo (anno-mese-giorno) 2012-11-01   -   2015-11-30

 Partecipanti

# participant  country  role  EC contrib. [€] 
1    CASA MARISTAS AZTERLAN

 Organization address address: ALIENDALDE AUZUNEA 6
city: DURANGO
postcode: 48200

contact info
Titolo: Mrs.
Nome: Ana
Cognome: Fernandez
Email: send email
Telefono: +34 94 6215470

ES (DURANGO) coordinator 18˙983.72
2    V.D.S. VACUUM DIECASTING SERVICE SA

 Organization address address: ZONE INDUSTRIELLE DE LA FOGE E
city: CHAILLY-MONTREUX
postcode: 1816

contact info
Titolo: Dr.
Nome: Christophe
Cognome: Bagnoud
Email: send email
Telefono: 410220000000

CH (CHAILLY-MONTREUX) participant 358˙919.50
3    DISTRIBUTION DE L ALUMINIUM COULE ELABORE SAS

 Organization address address: ZONE INDUSTRIELLE
city: VAYRAC
postcode: 46110

contact info
Titolo: Mr.
Nome: Matthieu
Cognome: Hede
Email: send email
Telefono: 33565324503

FR (VAYRAC) participant 262˙259.60
4    ALUMINIO INYECTADO ALIASA SL

 Organization address address: CARRETERA BILBAO VITORIA KM 22
city: IGORRE
postcode: 48140

contact info
Titolo: Mr.
Nome: Mikel
Cognome: Egiazu
Email: send email
Telefono: +34 946315011

ES (IGORRE) participant 178˙527.90
5    SCHMALE & SCHULTE GMBH

 Organization address address: AN DER BELLMEREI 1
city: LUDENSCHEID
postcode: 58566

contact info
Titolo: Mr.
Nome: Steffen
Cognome: Greis
Email: send email
Telefono: 492352000000

DE (LUDENSCHEID) participant 146˙177.78
6    RUFFINI SA

 Organization address address: AVDA COMPOSITOR BIZET 2
city: RUBI
postcode: 8191

contact info
Titolo: Mr.
Nome: Jose Maria
Cognome: Ripol
Email: send email
Telefono: 34935860125

ES (RUBI) participant 141˙504.45
7    CHEM-TREND (DEUTSCHLAND) GMBH

 Organization address address: GANGHOFERSTRASSE 47
city: MAISACH GERNLINDEN
postcode: 82216

contact info
Titolo: Mr.
Nome: Norbert
Cognome: Ehlers
Email: send email
Telefono: 494053000000

DE (MAISACH GERNLINDEN) participant 8˙627.00
8    FUNDACIO EURECAT

 Organization address address: AVENIDA UNIVERSITAT AUTONOMA 23
city: CERDANYOLA DEL VALLES (BARCELONA)
postcode: 8290

contact info
Titolo: Mr.
Nome: Fernando
Cognome: Porcel
Email: send email
Telefono: 34935944700

ES (CERDANYOLA DEL VALLES (BARCELONA)) participant 0.00
9    FUNDACIO PRIVADA ASCAMM

 Organization address address: "AVENIDA UNIVERSITAT AUTONOMA , PARC TECNOLOGIC DEL VALLES 23"
city: CERDANYOLA DEL VALLES
postcode: 8290

contact info
Titolo: Mr.
Nome: Fernando
Cognome: Porcel
Email: send email
Telefono: 34935944700

ES (CERDANYOLA DEL VALLES) participant 0.00
10    TECHNISCHE UNIVERSITAT BRAUNSCHWEIG

 Organization address address: POCKELSSTRASSE 14
city: BRAUNSCHWEIG
postcode: 38106

contact info
Titolo: Dr.
Nome: Helge
Cognome: Pries
Email: send email
Telefono: +49 0 531 3910

DE (BRAUNSCHWEIG) participant 0.00

Mappa


 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

alternative    simulation    light    adaptable    foundries    vacuum    die    quality    aluminium    significantly    market    special    alloys    mechanical    performance    castings    environmentally    stability    hpdc    industry    complexity    software    casting    sme    innovative    reduce    casters    recycled    welding    porosities    vehicles    soundcast    melt    porosity    inherent    optimization    technologies    pressure    fabrication    weight    alloy    treatment    assisted    scientists    weldable   

 Obiettivo del progetto (Objective)

'The necessity of preserving resources and to reduce environmental pollution makes light weight concepts and recycling highly interesting for the transportation market, being light weight essential for newly developed electric and hybrid vehicles.

At the present, the use of aluminium high pressure die castings for structural applications in the automotive industry is limited due the presence of porosity inherent to the fabrication process. High vacuum processes can reduce porosity significantly, but both the capital investment and the process costs are very high.

On the other hand, the use of cheaper adaptable vacuum systems it is still not very popular in SME foundries, despite of significant technological improvements during the last years; this is mainly because of the complexity of this process, the need for improved process stability and deeper metallurgical knowledge of the alloys used in these new applications.

The aim of the SOUNDCAST project is to provide the SME die caster with an innovative and environmentally friendly technology to produce sound and weldable high performance castings by a low cost vacuum assisted high pressure die casting (VPDC) process.

During the project the link between the most important parameters that enhance porosity will be established, and a versatile technology package which optimizes the whole fabrication process will be developed including: - Numerical simulation of die filling and solidification - Special die design - Use of a “state of the art vacuum” valve - HPDC process parameter optimization - Optimized die and shot sleeve lubrication for welding applications - Development of quality control software - Development of a new recycled alloy(s) with high mechanical properties - Melt and heat treatment optimization for the new recycled alloy(s) - Development of a new laser welding process at reduced pressure The developed know-how and technologies will be demonstrated and validated in SME foundries.'

Introduzione (Teaser)

EU-funded scientists are developing innovative, more environmentally friendly technologies to make stronger die castings.

Descrizione progetto (Article)

The drive for improved fuel efficiencies in the automobile industry has led to continuing growth in aluminium die casting. Larger and more complex parts are being cast and this has set new challenges to die casters in their quest for improved quality and productivity.

Porosities that are inherent to the fabrication process are limiting widespread use of aluminium high-pressure die casting (HPDC). Although inexpensive adaptable high-vacuum processes are significantly reducing porosities, the high complexity of this process has made die casters brush aside this alternative.

Scientists initiated the EU-funded project 'Vacuum-assisted high pressure die castings with reduced porosity at low cost' (http://www.soundcastproject.eu/ (SOUNDCAST)) to produce weldable high-performance castings using a low-cost vacuum-assisted HPDC.

The optimised fabrication technology should enable large, thin-walled and complicated component development with recycled aluminium alloys of minimal porosity and excellent mechanical and welding properties.Use of alternative recycled alloy will not only cut down fabrication costs but also carbon dioxide emissions. Developing new innovative control software suitable for low-cost vacuum-assisted HPDC processes will ensure process stability and casting quality of SOUNDCAST technology. The benefits will also be applied to conventional HPDC processes.

To date, scientists have fabricated a die for evaluating alloy mechanical properties and the vacuum-assisted HPDC. Porosities were significantly reduce using simulation tools and a special vacuum system to optimise HPDC process parameters. A new recycled alloy with improved mechanical properties was also developed through microalloying.

A software quality control system is already available for optimising recycled alloy melt treatment. Furthermore, scientists have selected a fully automatic die spraying system and die lubricants, and also optimised their process parameters.

By dint of project members' work, the aluminium component market should extend to lower-class vehicles. With low-cost high-quality technologies, the European casting sector will be able to compete with low-wage countries.

Altri progetti dello stesso programma (FP7-SME)

SUBCTEST (2008)

Development of novel Non Destructive Testing (NDT) techniques and autonomous robots to be deployed by Remote Operating Vehicles (ROVs) for the sub-sea inspection of offshore structure welds

Read More  

APTAR (2009)

"GLOBAL SOLUTION FOR SLAUGHTERHOUSES, TANNERIES AND PHYTOSANITARY SECTORS: TREATMENT OF CATEGORY 3 ANIMAL WASTES AND PRODUCTION HIGH VALUE PRODUCT WITH BIO-PESTICIDE PROPERTIES"

Read More  

BARLEYBOOST (2013)

Boosted barley utilisation and consumption in the EU for better health

Read More