New process for high strength cast aluminium applications

Purpose and goal

The main purpose was to evaluate the ablation casting process with respect to both component properties and sand and binder recycling. The goal fulfillment for the project is considered to be good. Overall, the project was able to demonstrate the potential of the process through property improvements on the cast component compared to conventional sand casting. It was also possible to show that the process does not allow any obstacles regarding recycling of the constituent molding materials. For an industrial implementation, however, further research and development is required.

Expected results and effects

The results showed that the dendritic arm distance was positively affected. Furthermore, a cautiously positive effect on the strength after heat treatment was noted for the ablated samples compared to the conventional ones. The results indicated that the process with certain additional R&D efforts could be industrialized and thus enable both property improvements and increase the possibility of homogeneous component properties. In the long run, this would mean that lighter components with more predictable properties could be developed.

Planned approach and implementation

The overall goal of the project was to evaluate the effect of the process, map the possibility of simulating the process and investigate the recycling of residual water and molding materials. An experimental method was chosen where a simplified test equipment was developed which allowed to try different process conditions. Based on the physical tests, conclusions could be drawn about the effect of the process as well as the possibility of recirculation of residual water. The tests also formed the basis for the simulation work.