New innovative lightweight application within the swedish foundry industri

Important results from the project

Casting flasks for sand moulds are exposed to elevated temperature, sometimes direct contact with molten metal, physical damage, and chemical substances. They are normally made from steel, and are therefore heavy and hard to handle. The aim with this project has been to evaluate how a lighter flask, made from composite material, will work throughout the casting process, what demands that are put on material and design, and which positive effects a composite flask would have on the casting process, cost, and working environment.

Expected long term effects

A demonstrator was produced, a casting flask made of polyseter-based polymer composite. The heat resistance as well as the mechanical stability showed to be insufficient for the application. However, the final weight loss for flask, mould, and casting, was estimated to 10-30% of the total wegiht. Therefore, it is believed to be some potential in the concept, but a necessary next step is to define an alternative composite material with the defined properties. A business plan can be made as the cost for this alternative material is known.

Approach and implementation

The project was started by making a specification for the application. A casting flask made of polymer composite served as demonstrator. Subsequently, trials were made and the results were evaluated. Already while making the specification, it was evident that the chosen material would not meet the requirements for heat resistance. Still, the study was performed, aiming to design and evaluate a methodology for studying how the working environment in the foundry process would be affected by using lighter casting flasks.