Development of a Degassing system for aluminium casting processing based on Ultrasound

"The research leading to these results has received funding from the European Union's Seventh Framework Programme managed by REA-Research Executive Agency <link http: ec.europa.eu research rea _blank external-link-new-window external link in new>

ec.europa.eu/research/rea

Partners	Main roles within the project
Project Coordination	Fundació Privada ASCAMM  is a leading design and industrial production Technology Centre with a strong focus on the development of high added value, market-oriented applications and the generation of proprietary product and process technology. Within the project it will be responsible, among other, for the model development and simulation of the Ultragassing prototype together with its testing with high-pressure die casting machine and vacuum. Ascamm will also contribute to the design of the transducer and sonotrode.
	Brunel centre for Advanced Solidification Research (BCAST) is an academic research centre focusing on both fundamental and applied research on solidification of metallic materials at Brunel University, UK. In the project it will provide its know-how on the effects of ultrasound on molten metal and will carry out experimental tests on the effects of the ultrasound on aluminium cast alloys as well as it will help with the technology optimisation and with the dissemination results.
	CERTA Kft. is an SME, which’s main business areas are the foundry, surface treatment and tool-making. Contributing with its extensive know-how on aluminium foundry, mainly focused on high pressure die casting and gravity casting, CERTA will be in charge of the validation of the Ultragassing prototype in high pressure dies casting and gravity casting.
	Hornos y metals S.A. (HORMESA) is a company specialized in the equipment, materials and turnkey solutions for non ferrous foundries, mainly Aluminium and Copper alloys. Based on its know-how on aluminium furnaces and alloy treatment, it will be devoted to define the equipment requirements, together with the design and construction of the prototype.
	Österreichisches Gießerei-Institut (ÖGI) is a non-university, non-profit research organization aiming to increase the fundamental understanding of materials and processes related to castings. It will be in charge of the X-ray computed tomography analysis, tensile tests and Ultragassing prototype test in gravity casting and low-pressure die casting. Moreover, it will contribute to the prototype design.
	ULTRASION SL is a company dedicated to design, manufacture and commercialize industrial solutions based on high power ultrasounds. Ultrasion will provide its know-how on ultrasound equipment design and fabrication and will take part in the design of the generator, transducer and sonotrode. Furthermore, it will be the IPR Manager.
	Vöcklabrucker Metallgießerei (VMG) is a foundry specialized in sand and permanent mould casting using gravity and low pressure filling techniques. Providing its broad know-how on aluminium foundry, particularly focused on low pressure die casting, it will be responsible for the validation of the Ultragassing prototype in low pressure die casting.

Outline

• In spite of the advantages of using aluminium light-alloys in applications requiring weight reduction, its use is limited by the quality and insufficient properties of the cast parts that suffer from gas porosity due to the presence of hydrogen in the molten metal. A clear example of this can be seen in the automotive sector (newly developed electric and hybrid vehicles).
  
  
• The current degassing techniques, based on the purge of a gas mixture through the melt have been proved to be expensive and harmful to one’s health (often containing chlorine or fluoride) and have shown limited efficiency.
  
  Ultragassing project targets at applying an ultrasonic degassing treatment on light-alloys, enhancing significantly the value of the cast parts produced by the EU foundries in terms of safety and quality.
  
  
• The application of the developed within this project technology will allow the participating SMEs to solve at least two  problems: (1) eliminate non safety and health hazardous technologies currently used and (2) improve degassing efficiency.
  
  
• Prototypes from the developed technology will be constructed and validated on 3 different industrial casting technologies (High Pressure Die Casting with vacuum; Low Pressure Die Casting; and Gravity Casting).
  
  
• The Ultragassing Project is an example of R&D project that will suppose an important improvement for the EU foundry sector of non-ferrous alloys.

• Complete elimination of harmful and environmentally unfriendly gases
• Elimination of rotational, porous and fragile contaminant components
• Optimized scheme that allows short treatment time with maximum benefit
• Applicability to both continuous and batch processes
• Applicability to a wide range of casting processes and liquid metals
• Removal of oxides in addition to dissolved gases 

Project Goals

1. Provide the European light-alloys foundries with an environmentally friendly and safe means to improve the quality of their cast parts by applying an ultrasound degassing treatment.
2. Establish a link between ultrasonic degassing parameters, melt quality and casting parameters, so as to develop a technology to be applied in different casting processes.
3. Demonstrate the efficiency of the developed technology as compared with the currently used by using the Ultragassing prototypes on standard production conditions.

In order to achieve the expected results,  the structure of the work plan lies in completing the following three phases:

• Phase 1: Research on ultrasound effect on molten metals and development of a numerical model of the process.
• Phase 2: Design and construction of prototypes.
• Phase 3:  Prototype validation on industrial machines and in industrial casting processes.

The project, that started the 1st of October 2011 and with a duration of 24 months, will achieved its set objectives through the following 9 Work Packages (WP):

Contact:    
Dr. Manel da Silva
Fundació Privada Ascamm
mdasilva@ascamm.com
Telf: + 34 93 594 47 00