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  • 1.
    Carlsson, Raul
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Elmquist, Lennart
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Johansson, Christian
    RISE - Research Institutes of Sweden, ICT, Acreo.
    Cast metal with intelligence - from passive to intelligent cast components2017In: 8th Conference on Smart Structures and Materials, SMART 2017 and 6th International Conference on Smart Materials and Nanotechnology in Engineering, SMN 2017, 2017, p. 550-560Conference paper (Refereed)
    Abstract [en]

    The paper describes an innovation project aiming to embed sensors into cast metal during the casting process. Important measurands are e.g. elongation, shear, temperature and vibration. In practice this means to turn metal components into also being digital components. This will respond to some of metal industrýs challenges; resource efficient design, increased value added for the casting sector, and general access to different possibilities of digitalization. Technical challenges lie in choices of sensor material to integrate during the casting process that maintains its sensor functionality after casting processing without degrading the mechanical strength of the metal component. Other challenges relate to signal interaction and interference between sensor and metal. To handle the technical challenges the innovation project gathers competence about metal casting and sensor technology. One goal of this innovation project is to develop an innovation platform that elevates the material based casting industry into a wholly or partially value and service based industry. Integration of sensors into cast components makes sensing functionality a natural property of metal, which in turn may turn metal into key components for the industrial digitalization.

  • 2.
    Carlsson, Raul
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Elmquist, Lennart
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Thore, Andreas
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Ahrentorp, Fredrik
    RISE - Research Institutes of Sweden, ICT, Acreo.
    Johansson, Christer
    RISE - Research Institutes of Sweden, ICT, Acreo.
    Israelsson, Björn
    SKF Mekan AB, Sweden.
    Connecting sensors inside smart castings2018Conference paper (Refereed)
    Abstract [en]

    The paper presents ongoing research on smart metal castings, meaning the technologicalinnovation of elevating cast metal components into metal components with integratedsensor functionality. Since the innovation targets aim straight at low cost industrial serialproduction, specific high cost and high-end solutions like inclusion of advancedelectronic equipment and after mounted sensors are not part of this innovationdevelopment. Integrating signal carriers inside metal castings to achieve metal castingswith sensor functionality requires robust solutions for connecting the sensor signal to thesensor interrogator and interpreter. The actual transmission of the signal may be donewirelessly or by wire. However, for several reasons there is a challenge with establishingan isolated and distinct connection between the sensor contact, and the contact at theexternal connection, regardless of whether it is to an antenna for wireless transmission orto a wire. This paper presents metallurgical challenges associated with choices ofmaterials, and combinations of metallurgical challenges and production process relatedchallenges, including the high melting temperatures. Aims are to find the rightcombinations of metal alloys, production simplicity, signal stability and robustness. Thepaper will present some of the tests made in the project so far. The project is run in aconsortium of the two Sweden-based industrial companies Husqvarna and SKF, and thetwo Swedish research institutes Swerea SWECAST and RISE Acreo.

  • 3.
    Elmquist, Lennart
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Carlsson, Raul
    RISE - Research Institutes of Sweden, Materials and Production, SWECAST.
    Johansson, Christer
    RISE - Research Institutes of Sweden, ICT, Acreo.
    Cast iron components with intelligence2018Conference paper (Refereed)
    Abstract [en]

    The paper describes a project with the aim to develop communicating and functional cast iron components in smart systems. The concept is based on sensors integrated into cast iron components; this will influence not only the component but also the casting process. Among the technical challenges is how to choose a sensor solution that cost-efficiently and with minimal environmental impact can be integrated into the component during the casting process, and especially without being damaged during mold filling and the high pouring temperature. Another challenge is how the iron will interact and interfere with sensor signals and whether an insulating intermediate material is needed or not. Integrating the sensors into the casting makes sensors a natural part of the component, which in turn can lead to more resource efficient designs, increased value added for the casting sector, and a general access to different possibilities of digitalization. The integrated sensors can be used for effective control and monitoring of components when in service and give information about for example how the component is used and what conditions it is exposed to. In other words, the component can tell when maintenance is needed or in worst cases, indicate that something is wrong before a failure will happen. Important measurands can e.g. be elongation, shear, temperature and vibration. Different combinations of sensor materials and insulating materials and their interaction with the cast iron have been investigated. It is shown how the interaction at the interface affects the microstructure and consequently the properties of the cast iron. In the case of insulating materials it is e.g. shown how air gaps are formed and in the case of sensor materials it is shown how a diffusion zone is formed and how this zone depends on the sensor material. How this diffusion zone affects the microstructure is discussed.

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