DOSHORMAT

DEGASSING MACHINE FOR ALUMINUM CASTING PROCESS BASED ON ULTRASOUND

 Partecipanti

Mappa

 Word cloud

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

 Obiettivo del progetto (Objective)

'Taking advantage of previous results achieved by ULTRAGASING (FP7-SME-2011-1), DOSHORMAT intends to optimize and develop two ready-to-market ultrasonic degassing machines for aluminium foundries that represent efficiency solutions for degassing molten aluminium. The degassing technology is one of the main components of quality assurance in casting industry. The quality of any as-cast material depends to a great extent on the amount of defects. One of the main defects in near-net shape casting processes is porosity. Currently used methods of degassing have drawbacks and limitations: involve using mixtures of expensive inert gas, health and environment hazards, strict safety rules, larger investment and maintenance costs, and/or low efficiency. The cavitation melt treatment presents a feasible alternative to current degassing techniques. However, before ULTRAGASSING project, there were not known applications of ultrasound to degas metallic melts on industrial scale and in regular casting processing. ULTRAGASSING has demonstrated the feasibility of using ultrasonic treatment to degas considerable volumes of melt in batch operations (up to 60 kg). This allowed the development of two conceptual prototypes for degassing aluminium alloys. Even though, there are still relevant points that must be improved in order to successfully introduce the machine in the market and exploit new market niches. The aim of DOSHORMAT is to improve and optimize the previous prototypes from ULTRAGASSING, adapting them to all the market needs, by developing one equipment specifically designed for HPDC and Gravity Casting and another for degassing much larger volumes, suitable for LPDC and, in general, for any casting activity. DOSHORMAT will improve the melt quality, reducing the gas content and removing the oxides, highly enhancing the quality and mechanical performance of the components produced (e.g. transport applications), while meeting the present and future environment regulations.'

Introduzione (Teaser)

The amount of lightweight aluminium in new cars is increasing, but current methods to get rid of hydrogen gas (H2) bubbles that create porosities are expensive, inefficient and hazardous. Novel ultrasonic technology is headed to market to keep aluminium on the road.

Descrizione progetto (Article)

Lightweight alloys play an important role in the design of new cars. In conventional gas engines, lowering the weight reduces fuel consumption and emissions. In new hybrid and electric cars, less weight to move around means longer distances before recharging. However, H2 introduced during the processing of aluminium alloys creates porosity that negatively impacts the performance of cast parts.

The EU-funded project http://www.doshormat.eu (DOSHORMAT) (Degassing machine for aluminum casting process based on ultrasound) is up-scaling degassing technology developed within the previous Seventh Framework Programme (FP7) project ULTRAGASSING. The method was shown to efficiently degas aluminium alloys at laboratory and pilot scales. DOSHORMAT is now optimising it with an eye on mass production. The team is focusing on the relationships among ultrasonic degassing parameters, casting parameters and melt quality to develop a versatile method capable of being tailored to a specific casting process.

Scientists have now designed two prototypes for aluminium degassing, one for high-pressure die casting and gravity casting and another for low-pressure die casting. This required adaptation of the ULTRAGASSING concepts for commercial implementation considering all aspects, including manufacturing costs, safety regulations, efficiency and market potential. Preliminary tests of the machines in an industrial laboratory have been completed and feasibility studies are being used to investigate new machine configurations to address specific production aspects.

The presence of H2 in molten melt during the aluminium alloy casting process affects product quality and performance, and current degassing methods face several challenges. DOSHORMAT is preparing promising ultrasonic degassing technology for commercialisation. It will solve current problems and provide the solution to future environmental regulations as well.