PROJECT

“Technology of simultaneous monitoring and control of the heat treatment process in the automatic production of high-pressure castings from light metal alloys, using tooling manufactured by additive 3D printing methods.”

co-funded by the European Union under Measure 1.1 Research, Development and Innovation of Enterprises, No. FEMA.01.01-IP.01-013/24.

Project type: Modular projects for the European Funds for Mazovia 2021–2027 programme.

Project objectives:

The main objective of the project is to develop an innovative technology for the heat treatment of HPDC castings, carried out directly at the casting station instead of through a complex, energy-inefficient and time-consuming process using separate tooling, which can be implemented for various casting alloys. As a result, there will be a significant improvement in the quality of services offered to customers across all industries requiring cast products from light metals with increased mechanical strength.

To enable the achievement of the main objective of the project, three key implementation stages have been planned:

Stage One (industrial research)

  • Conducting research using the standard process and laboratory techniques, enabling the acquisition of reference data for standard processes as well as the verification of detailed assumptions and refinement of modernisation designs;
    Development of detailed concepts and designs for the modernisation of casting cells.
  • Dedicated technological tooling for zinc and aluminium parts will be designed and manufactured. An external R&D service will be carried out as part of subcontracting. 

Stage Two (development work)

  • Transfer of the developed concept to actual casting cells used for the production of light metal alloy components;
  • Verification of the effectiveness of the implemented treatment during initial trials and determination of detailed heat treatment parameters for future production processes.

Materials for the construction of a demonstration line will be designed and manufactured. Raw materials and auxiliary materials will be purchased. An external R&D service will be carried out as part of subcontracting.

Stage Three (development work)

  • Preparation and commencement of long-term verification of the correctness of operation and stability of the results obtained within the innovative and fully implemented treatment process, in line with the main objective of the project.

Materials for technological testing, raw materials and auxiliary materials will be designed and manufactured.

The result of the R&D work will be a process innovation in the form of an innovative casting process that enables the enhancement of the mechanical properties of light metal alloys through heat treatment in an automatic cycle carried out directly at the station where they are produced.

The developed technology allows the production of high-pressure castings from non-ferrous alloys characterised by reduced porosity and a surface quality that ensures tightness.

Target group: the automotive and hydraulic industries.

These market segments require products with high internal structural quality, meaning the absence of porosity, as well as high external surface quality that ensures tightness during tests simulating the operating conditions of the end-use equipment.

Project value:

10 410 723,04 PLN

Amount of contribution from the European Funds:

3 513 407,66 PLN

signs EF Mazovia