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  • 1.
    Andersson, Peter
    et al.
    RISE, Swerea, Swerea KIMAB.
    Gotte, Anders
    RISE, Swerea, Swerea SWECAST.
    Värmeledningsförmåga hos formmaterial2011Report (Refereed)
    Abstract [sv]

    I den första delen av studien tillverkades och bestämdes värmeledningsförmågan för samtliga provkroppar i olika kvarts/fältspatsander från Baskarpsand. Sanderna skiljer sig åt i medelkornstorlek och kornstorleksfördelning. Två olika självhärdande bindemedel, alfaset och furan, användes. I studiens senare del tillverkades och bestämdes värmeledningsförmågan för provkroppar också i sander baserade på andra mineraler. Dessutom undersöktes ytterligare ett bindemedel, nämligen Coldbox. Resultat för Coldbox redovisas i rapporten, då den inte kommer att ingå i någon publikation. Resultaten från de övriga försök kommer att publiceras i en vetenskaplig tidskrift inom något av områdena gjuteriteknik eller mineralogi. För att tillgodose de tilltänka tidskrifternas publiceringsregler, redovisas inte resultaten för dessa i denna rapport.

  • 2.
    Bladh, Madeleine
    et al.
    RISE, Swerea, Swerea SWECAST.
    Wessén, M.
    Jönköping University.
    Dahle, A.K.
    University of Queensland.
    Shear band formation in shaped rheocast aluminium component at various plunger velocities2010In: Transactions of Nonferrous Metals Society of China, ISSN 1003-6326, E-ISSN 2210-3384, Vol. 20, no 9, p. 1749-1755Article in journal (Refereed)
  • 3.
    Carlsson, Andreas
    RISE, Swerea, Swerea SWECAST.
    Simulation of thin walled ductile iron2010In: Foundry Trade Journal, ISSN 0015-9042, Vol. 184, no 3678, p. 248-249Article in journal (Refereed)
  • 4.
    Carlsson, Raul
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Elmquist, Lennart
    RISE - Research Institutes of Sweden, Swerea, Swerea 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.

  • 5.
    Carlsson, Raul
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Elmquist, Lennart
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Thore, Andreas
    RISE - Research Institutes of Sweden, Swerea, Swerea 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.

  • 6.
    Ceschini, Lorella
    et al.
    University of Bologna, Italy.
    Morri, Allesandro
    University of Bologna, Italy.
    Toschi, Stephania
    University of Bologna, Italy.
    Bjurenstedt, Anton
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Seifeddine, Salem
    Jönköping University, Sweden.
    Influence of sludge particles on the fatigue behavior of Al-Si-Cu secondary aluminium casting alloys2018In: Metals, ISSN 2075-4701, Vol. 8, no 4, article id 268Article in journal (Refereed)
    Abstract [en]

    Al-Si-Cu alloys are the most widely used materials for high-pressure die casting processes. In such alloys, Fe content is generally high to avoid die soldering issues, but it is considered an impurity since it generates acicular intermetallics (β-Fe) which are detrimental to the mechanical behavior of the alloys. Mn and Cr may act as modifiers, leading to the formation of other Fe-bearing particles which are characterized by less harmful morphologies, and which tend to settle on the bottom of furnaces and crucibles (usually referred to as sludge). This work is aimed at evaluating the influence of sludge intermetallics on the fatigue behavior of A380 Al-Si-Cu alloy. Four alloys were produced by adding different Fe, Mn and Cr contents to A380 alloy; samples were remelted by directional solidification equipment to obtain a fixed secondary dendrite arm spacing (SDAS) value (~10 µm), then subjected to hot isostatic pressing (HIP). Rotating bending fatigue tests showed that, at room temperature, sludge particles play a detrimental role on fatigue behavior of T6 alloys, diminishing fatigue strength. At elevated temperatures (200◦C) and after overaging, the influence of sludge is less relevant, probably due to a softening of the α-Al matrix and a reduction of stress concentration related to Fe-bearing intermetallics. 

  • 7.
    Diószegi, A.
    et al.
    Jönköping University.
    Fourlakidis, Vasilios
    RISE, Swerea, Swerea SWECAST.
    Svensson, I.L.
    Jönköping University.
    Fracture mechanics of gray cast iron2010Conference paper (Refereed)
  • 8.
    Diószegi, A.
    et al.
    Jönköping University.
    Lora, R.
    Jönköping University.
    Fourlakidis, Vasilios
    RISE, Swerea, Swerea SWECAST.
    Dynamic coarsening of austenite dendrite in lamellar cast iron part 1: Investigation based on interrupted solidification2014Conference paper (Refereed)
  • 9.
    Elmquist, Lennart
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Brehmer, Aron
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Schmidt, Pål
    Volvo GTT, Sweden.
    Israelsson, Björn
    SKF Mekan AB, Sweden.
    Residual stresses in cast iron components – Simulated results verified by experimental measurements2018In: Mater. Sci. Forum, 2018, p. 326-333Conference paper (Refereed)
    Abstract [en]

    The aim of this work was to investigate how accurately residual stresses can be simulated in a cast component. The reason why this is important is that a simulation that also considers residual stresses can be used to design cast components more weight- and cost-efficient. The verification was done by comparing simulated results with physical measurements on cylinders made of ductile iron. The measurements were performed with two methods, sectioning and holedrilling. These methods were applied on both as-cast and machined cylinders. The simulations were based on process data from casting trials and material data from the simulation software database. The material data for the heat conductivity of the molding sand was fitted to get a good conformity between measured and simulated temperatures. This was done to ensure that the residual stress simulation used a relevant temperature history. It turned out that the simulation was in good agreement with results from the sectioning measurements of the axial stress while results from the hole-drilling measurements were contradictive. These results were contradictive for both as-cast and machined cylinders. It can therefore be concluded that residual stresses measured by the sectioning method resulted in good conformity with the simulated σz stresses. It was also concluded that the feeders, acting as extra heat sources, affects residual stresses locally and contributes to differences in stresses beneath the feeders, compared to corresponding areas between the feeders. It was also found that the resolution of the mesh needs to be finer to take into account changes in the stresses with increments in depth when using the hole drilling method.

  • 10.
    Elmquist, Lennart
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Carlsson, Raul
    RISE - Research Institutes of Sweden, Swerea, Swerea 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.

  • 11.
    Ferraro, S.
    et al.
    University of Padova.
    Bjurenstedt, A.
    Jönköping University.
    Seifeddine, Salem
    RISE, Swerea, Swerea SWECAST.
    On the Formation of Sludge Intermetallic Particles in Secondary Aluminum Alloys2015In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 46, no 8, p. 3713-3722Article in journal (Refereed)
  • 12.
    Fourlakidis, Vasilios
    RISE, Swerea, Swerea SWECAST.
    A study on ductile iron production without the use of feeders2011Conference paper (Refereed)
  • 13.
    Fourlakidis, Vasilios
    RISE, Swerea, Swerea SWECAST.
    A study on ductile iron production without the use of feeders2013In: Foundry Trade Journal International, ISSN 1758-9789, Vol. 187, no 3702, p. 60-62Article in journal (Refereed)
  • 14.
    Fourlakidis, Vasilios
    et al.
    Jönköping University, Sweden.
    Belov, Ilja
    Jönköping University, Sweden.
    Diószegi, Attila
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Strength prediction for pearlitic lamellar graphite iron: Model validation2018In: Metals, ISSN 2075-4701, Vol. 8, no 9, article id 684Article in journal (Refereed)
    Abstract [en]

    The present work provides validation of the ultimate tensile strength computational models, based on full-scale lamellar graphite iron casting process simulation, against previously obtained experimental data. Microstructure models have been combined with modified Griffith and Hall–Petch equations, and incorporated into casting simulation software, to enable the strength prediction for four pearlitic lamellar cast iron alloys with various carbon contents. The results show that the developed models can be successfully applied within the strength prediction methodology along with the simulation tools, for a wide range of carbon contents and for different solidification rates typical for both thin-and thick-walled complex-shaped iron castings.

  • 15.
    Fourlakidis, Vasilios
    et al.
    RISE, Swerea, Swerea SWECAST.
    Diaconu, L.V.
    University of Miskolc.
    Diószegi, A.
    Jönköping University.
    Effects of carbon content on the ultimate tensile strength in gray cast iron2010Conference paper (Refereed)
  • 16.
    Fourlakidis, Vasilios
    et al.
    RISE, Swerea, Swerea SWECAST.
    Diószegi, A.
    Jönköping University.
    A generic model to predict the ultimate tensile strength in pearlitic lamellar graphite iron2014In: Materials Science & Engineering: A, ISSN 0921-5093, E-ISSN 1873-4936, Vol. 618, p. 161-167Article in journal (Refereed)
  • 17.
    Fourlakidis, Vasilios
    et al.
    RISE, Swerea, Swerea SWECAST.
    Lora, R.
    Jönköping University.
    Diószegi, A.
    Jönköping University.
    Dynamic coarsening of austenite dendrite in lamellar cast iron part 2: The influence of carbon composition2014Conference paper (Refereed)
  • 18.
    Fourlakidis, Vassilios
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Diaconu, Lucian V.
    Jönköping University, Sweden.
    Diószegi, Attila
    Jönköping University, Sweden.
    Strength prediction of lamellar graphite iron: From Griffith’s to hall-petch modified equation2018In: Materials Science Forum, 2018, Vol. 925, p. 272-279Conference paper (Refereed)
    Abstract [en]

    Traditionally, ultimate tensile strength (UTS) is used as the main property for the characterization of lamellar graphite iron (LGI) alloys under static loads. The main models found in the literature for predicting UTS of pearlitic lamellar graphite iron are based on either regression analysis on experimental data or on modified Griffith or Hall-Petch equation. In pearlitic lamellar graphite iron the primary austenite dendritic network, transformed to pearlite, reinforces the bulk material while the distance between those pearlite grains, defines the maximum continuous defect size in the bulk material. Recently the novel parameter of the Diameter of Interdendritic Space has been used to express the flow length in a modified Griffith equation for the prediction of the UTS in LGI. Nevertheless this model neglects the strengthening effect of the pearlite lamellar spacing within the perlite grains. A model based on modified Hall-Petch equation was developed in this work. The model considers the effect of both microstructure parameters and covers a broad spectrum of microstructure sizes typical for complex shape castings with various wall thicknesses.

  • 19.
    Ghasemi, Rohollah
    et al.
    Jönköping University, Sweden.
    Elmquist, L.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Ghassemali, E.
    Jönköping University, Sweden.
    Salomonsson, K.
    Jönköping University, Sweden.
    Jarfors, A. E. W.
    Jönköping University, Sweden.
    Abrasion resistance of lamellar graphite iron: Interaction between microstructure and abrasive particles2018In: Tribology International, ISSN 0301-679X, E-ISSN 1879-2464, Vol. 120, p. 465-475Article in journal (Refereed)
    Abstract [en]

    This study focuses on abrasion resistance of Lamellar Graphite Iron (LGI) using microscratch test under constant and progressive load conditions. The interactions between a semi-spherical abrasive particle, cast iron matrix and graphite lamellas were physically simulated using a sphero-conical indenter. The produced scratches were analysed using LOM and SEM to scrutinise the effect of normal load on resulting scratch depth, width, frictional force, friction coefficient and deformation mechanism of matrix during scratching. Results showed a significant matrix deformation, and change both in frictional force and friction coefficient by increase of scratch load. Furthermore, it was shown how abrasive particles might produce deep scratches with severe matrix deformation which could result in graphite lamella's coverage and thereby deteriorate LGI's abrasion resistance.

  • 20.
    Golpayegani, A.
    et al.
    Chalmers University of Technology.
    Liu, F.
    Chalmers University of Technology.
    Svensson, Henrik
    RISE, Swerea, Swerea SWECAST.
    Andersson, M.
    Chalmers University of Technology.
    Andrén, H.-O.
    Chalmers University of Technology.
    Microstructure of a creep-resistant 10 pct chromium steel containing 250 ppm boron2011In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 42, no 4, p. 940-951Article in journal (Refereed)
  • 21.
    Gustafsson, Erik
    et al.
    RISE, Swerea, Swerea SWECAST.
    Strömberg, N.
    Jönköping University.
    Shape optimization of castings by using successive response surface methodology2008In: Structural and multidisciplinary optimization (Print), ISSN 1615-147X, E-ISSN 1615-1488, Vol. 35, no 1, p. 11-28Article in journal (Refereed)
  • 22.
    Hallström, Frida
    RISE, Swerea, Swerea SWECAST.
    Joining metal and composites makes good sense2008In: Foundry Trade Journal, ISSN 0015-9042, Vol. 181, no 3651, p. 22-23Article in journal (Refereed)
  • 23.
    Hammersberg, Peter
    et al.
    Chalmers University of Technology, Sweden.
    Hamberg, Kenneth
    Chalmers University of Technology, Sweden.
    Borgström, Henrik
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Lindkvist, Joachim
    Volvo Powertrain, Sweden.
    Björkegren, Lars Erik
    LEB Casting Technology, Sweden.
    Variation of tensile properties of high silicon ductile iron2018In: Mater. Sci. Forum, 2018, p. 280-287Conference paper (Refereed)
    Abstract [en]

    The casting processes are characterized by complex relationships between predictors and responses. It is the fundamental understanding of these complex relationships that often involves hundreds of factors, which improves quality without losing productivity and raising cost. In this work, cast solid solution strengthened ferritic spheroidal graphite irons GJS-500-14 and GJS-600-10 (EN 1563:2012) have been evaluated. These materials offer stronger components with good machinability owing to their even hardness properties. In this case the predictors are chemical composition, gating layout, foundry set-up, testing procedure and equipment etc. and the responses are the tensile properties (Rp0.2, Rm, A5). Here 200 tensile specimens compiled from industrial foundry melts from over 30 years of research have created a state-of-the-art platform for statistical engineering in order to perform Exploratory Data Analysis (EDA) and data visualization. This statistical platform has provided new insight on how foundries should treat complex relationships between predictors and responses in order to identify sources of variation and interaction effects.

  • 24.
    Holmgren, Mats
    RISE, Swerea, Swerea SWECAST.
    External reuse of waste from foundries: Experience, limits and laws in the EU2012In: Foundry Trade Journal International, ISSN 1758-9789, Vol. 186, no 3694, p. 124-126Article in journal (Refereed)
  • 25.
    Holmgren, Mats
    RISE, Swerea, Swerea SWECAST.
    External reuse of waste from foundries: experience, limits and lawsin Eu2010Conference paper (Refereed)
  • 26.
    Holmgren, Mats
    et al.
    RISE, Swerea, Swerea SWECAST.
    Nayström, Peter
    RISE, Swerea, Swerea SWECAST.
    The Green foundry2008Conference paper (Refereed)
  • 27.
    Hryha, E.
    et al.
    Chalmers University of Technology.
    Borgström, Henrik
    RISE, Swerea, Swerea SWECAST.
    Sterky, K.
    Chalmers University of Technology.
    Nyborg, L.
    Chalmers University of Technology.
    Influence of the steel powder type and processing parameters on the debinding of PM compacts with gelatin binder2014In: Journal of thermal analysis and calorimetry (Print), ISSN 1388-6150, E-ISSN 1588-2926, Vol. 118, no 2, p. 695-704Article in journal (Refereed)
  • 28.
    Lauenstein, Åsa
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    ACDC Test och Demo för hållbara gjutna komponenter2017Report (Other academic)
    Abstract [sv]

    Projektet ACDC syftar till att vidareutveckla Swerea SWECASTs Test- ochdemonstrationsanläggning för utveckling av gjutprocesser och gjutna prototyperoch produkter i riktning mot det övergripande målet att strukturen ska utformas såatt en långsiktig och hållbar drift av anläggningen kan genomföras.T&D-anläggningen är en viktig resurs för forsknings- och uppdragsverksamhetenpå SWECAST. Grunden utgörs av en pågående verksamhet i försöksgjuteriet somtidigare fokuserat på utbildning av gjuterioperatörer och praktiska provgjutningar,men som under en följd av år successivt har breddats till att även inkludera såväldesign- och beredningsprocess som efterkontroll av material och komponenter.Verksamheten inkluderar även en 3D-printer för sandformar och kärnor. På siktär strävan att även inkludera utvärdering av den färdiga komponentens prestandagenom exempelvis utmattningsprovning, korrosionstester och fälttester.Denna delrapport beskriver det arbete som bedrivits under första halvan avprojektet ACDC för att omvandla det tidigare utbildningsjuteriet till en effektivoch funktionell försöksanläggning, hitta nya samverkansformer internt på Swecastsamt ta fram en bärkraftig metodik för framställning av gjutna koncept inomprojekt och uppdrag.Inom projektet ACDC återstår flera viktiga punkter att slutföra under 2017. Enkonkret vision om långsiktig hållbarhet för T&D-anläggningen ska formuleras.Examensarbetet om virtuella modeller ska slutföras och utvärderas. Slutligen ärambitionen att dessutom utforma en modell för Framtidens Gjuteri.

  • 29.
    Ledell, Stefan Gustafsson
    RISE, Swerea, Swerea SWECAST.
    Can thin-wall castings be simulated?2009In: Foundry Trade Journal, ISSN 0015-9042, Vol. 183, no 3666, p. 172-173Article in journal (Refereed)
  • 30.
    Mardan, N.
    et al.
    Linköping University.
    Klahr, Roger
    RISE, Swerea, Swerea SWECAST.
    Combining optimisation and simulation in an energy systems analysis of a Swedish iron foundry2012In: Energy, ISSN 0360-5442, E-ISSN 1873-6785, Vol. 44, no 1, p. 410-419Article in journal (Refereed)
  • 31.
    Mardan, N.
    et al.
    Linköping University.
    Klahr, Roger
    RISE, Swerea, Swerea SWECAST.
    Karlsson, M.
    Linköping University.
    Industrial decision making for energy efficiency: combining optimisation and simulation2011Conference paper (Refereed)
  • 32.
    Nayyar, V.
    et al.
    Chalmers University of Technology.
    Svensson, Henrik
    RISE, Swerea, Swerea SWECAST.
    König, M.
    Scania CV AB.
    Berglund, A.
    KTH Royal Institute of Technology.
    Nyborg, L.
    Chalmers University of Technology.
    Investigation of microstructure and material properties for 18 different graphitic cast iron model materials with focus on Compacted Graphite Iron (CGI)2013In: International Journal of Microstructure and Materials Properties, ISSN 1741-8410, E-ISSN 1741-8429, Vol. 8, p. 262-282Article in journal (Refereed)
  • 33.
    Rawashdeh, Nathir
    et al.
    German Jordanian University, Jordan.
    Khraisat, Walid
    The University of Jordan, Jordan.
    Borgström, Henrik
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Pinning effect of pores on grain growth in sintered steel2017In: Jordan Journal of Mechanical and Industrial Engineering, ISSN 1995-6665, Vol. 11, no 2, p. 73-78Article in journal (Refereed)
    Abstract [en]

    The effect of pore drag on grain growth is one of the most frequent effects encountered in the last stage of sintering. Therefore, the understanding of the effect of microstructure and pore location, pore morphology on grain growth is essential. Here a migrating grain boundary interacts with pores and other grain boundaries such that its structure and energy vary during grain growth. Consequently, it is of great interest to see whether the grain boundary energy decreases or increases during the interaction between migrating grain boundaries and pores. In this paper, the conditions for grain boundary migration and pinning are related to pore curvature and illustrated theoretically and experimentally.

  • 34.
    Raza, Mohsin
    et al.
    Mälardalen University, Sweden ; TPC Components AB, Sweden.
    Svenningsson, Roger
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Irwin, Mark
    TPC Components AB, Sweden.
    Fägerström, Björn
    Mälardalen University, Sweden.
    Jarfors, Anders E. W.
    Jönköping University, Sweden.
    Effects of Process Related Variations on Fillablity Simulation of Thin-Walled IN718 Structures2018In: International Journal of metalcasting, ISSN 1939-5981, E-ISSN 2163-3193, Vol. 12, no 3, p. 543-553Article in journal (Refereed)
    Abstract [en]

    Simulation tools have improved significantly and are now capable of accurately predicting mould filling behavior. The quality of prediction is highly dependent on material properties and set-up of boundary conditions for the simulation. In this work material properties were measured and casting conditions were analyzed to accurately replicate the casting process in simulation. The sensitivity of the predictions to minor process variations commonly found in foundries was evaluated by comparing simulation and cast samples. The observed discrepancies between simulation and cast samples were evaluated and discussed in terms of their dependency on process variations. It was concluded that the simulation set-up was capable of reasonable predictions and could replicate the asymmetry of the filling however did not accurately predict the absolute value of the unfilled area. It was discovered that asymmetric flow due to variations in the orientation of the casting mould during filling could have greater influence on the predictions than the actual variation in fill time. The quality of simulation is dependent on equipment and techniques used in the foundry as well as the metallurgical model to simulate the process. © 2017, The Author(s).

  • 35.
    Seifeddine, Salem
    et al.
    RISE, Swerea, Swerea SWECAST.
    Poletaeva, D.
    Jönköping University.
    Ghorbani, M.
    Jönköping University.
    Jarfors, A.
    Jönköping University.
    Heat treating of high pressure die cast components: Challenges and possibilities2014Conference paper (Refereed)
  • 36.
    Siafakas, Dimitrios
    et al.
    Jönköping University, Sweden.
    Matsushita, Taishi
    Jönköping University, Sweden.
    Lauenstein, Åsa
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Ekengård, Johan
    Sandvik SRP, Sweden.
    Jarfors, Anders E. W.
    Jönköping University, Sweden.
    The influence of deoxidation practice on the as-cast grain size of austenitic manganese steels2017In: Metals, ISSN 2075-4701, Vol. 7, no 6Article in journal (Refereed)
    Abstract [en]

    The effect of in-situ precipitating particles on the grain size of Al-Ti-treated and untreated Hadfield steel cast in a pilot scale environment was studied. Hadfield steel was melted in an induction furnace and cast in Y-Block samples. Light Optical Microscopy (LOM) and the intercept method were utilized for the grain size measurements. Additionally, Thermo-Calc Software TCFE7 Steels/Fe-alloys database version 7 was used for thermodynamic equilibrium calculations of the mole fraction of particles. The planar disregistry values between the austenite and the precipitating particles were calculated. It was observed that increasing oxide content in samples with low Ti(CN) content resulted in a finer microstructure, while increasing the Ti(CN) content under similar oxide content levels led to a coarser microstructure. The potency of each type of particle to nucleate austenitic grains was determined. Spinel (MnAl2O4, MgAl2O4) particles were characterized as the most potent, followed by olivine (Mn2SiO4), corundum (Al2O3, TiO2), and finally Ti(CN), the least potent particle.

  • 37.
    Siafakas, Dimitrios
    et al.
    Jönköping University, Sweden.
    Matsushita, Taishi
    Jönköping University, Sweden.
    Lauenstein, Åsa
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Ekerot, Sven
    Comdicast AB, Sweden.
    Jarfors, Anders E. W.
    Jönköping University, Sweden.
    A particle population analysis in Ti- and Al- deoxidized Hadfield steels2018In: International Journal of Cast Metals Research, ISSN 1364-0461, E-ISSN 1743-1336, Vol. 31, no 3, p. 125-134Article in journal (Refereed)
    Abstract [en]

    A quantitative analysis of the amount, size and number of particles that precipitate in situ in titanium- and aluminium-treated Hadfield steel cast during pilot-scale experiments has been performed. SEM with EDS and automated particle analysis abilities was utilized for the analysis. Additionally, Thermo-Calc was used for thermodynamic calculations and Magma 5 for solidification and cooling simulations. Predicted particles sizes calculated with a model based on the Ostwald ripening mechanism were compared with the experimental data. The effect of solute availability, cooling rate and deoxidation practice on the particle population characteristics was determined. It was concluded that the amount, size and number of precipitating particles in Hadfield steel castings is possible to be controlled according to certain requirements by a careful selection of proper additives in proper amounts and also by the optimization of the casting process in aspects of deoxidation timing and control of the cooling rate of the castings.

  • 38.
    Sibeck, Lennart
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Högpresterande gjutna aluminiumkomponenter2017Report (Other academic)
    Abstract [en]

    The project is a continuation and reporting of 3 year G projects in high performance Al alloys, HPAL.

    The work has focused on gaining knowledge especially in two areas; how to increase the strength and toughness of commercial Al-Si alloys at elevated temperatures and at room temperature. A literature study has shown how to achieve very good properties through the addition of various alloy additions and the use of customized alloys. In this project the starting point has been

    conventional alloys, and better properties would be achieved both by optimizing alloying elements and by minimizing defect levels with improved gating system.

    A new test specimen model was designed in CAD. To show the influence of the melt flow on defects, and hence strength, the model was made in two versions; good resp. less good injection system. Sand moulds were produced using a 3D sand printer. The results of the tensile test became unexpected; the difference between the groups was very small.

    In the work of alloy with improved ductility, an alloy from the literature was chosen, using Cr to partially replace Mg. As starting alloy, AlSi7Mg was selected. Test specimens were produced in a gradient furnace, where a controlled solidification helps to minimize defects. The result shows that the Cr addition gave a slight increase in toughness, but after conventional aging, a severe reduction in strength was achieved. Aging at longer times gave strength comparable to the basic alloy without Cr, but lower than the alloy from literature.

    Directional solidification trials has illustated the importance of silicon as an alloying element on the mechanical properties at elevated temperature (230 C) for an Al-Si9-Cu3-Fe-alloy. An increase of silicon from 9,1 to 12,4 % improves the mechanical properties at room temperature as well as at elevated temperatures. Compared to the base-alloy EN AC 46000 (STENAL 460) the increase in yield strength, ultimate tensile strength and fracture elongation was 49, 17 and 20 % respectively at 230 C. The corresponding increase at room temperature was 16, 22 and 69 % respectively. A Master Thesis work at Jönköping University demonstrate the influnce of silicon, cobolt and nickel on the elevated temperature mechanical properties for Al-Si-alloys.

  • 39.
    Sjögren, Torsten
    et al.
    SP Technical Research Institute of Sweden.
    Svensson, Henrik
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Study of the eutectoid transformation in grey cast irons and its effect on mechanical properties2011Conference paper (Refereed)
  • 40.
    Solding, Petter
    RISE, Swerea, Swerea SWECAST.
    Cutting the MWhs for increased competitiveness2009In: Foundry Trade Journal, ISSN 0015-9042, Vol. 183, no 3667, p. 212-213Article in journal (Refereed)
  • 41.
    Solding, Petter
    RISE, Swerea, Swerea SWECAST.
    Reducing energy use through simulation2007In: Foundry Trade Journal, ISSN 0015-9042, Vol. 181, no 3648, p. 282-283Article in journal (Refereed)
  • 42.
    Solding, Petter
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Gullander, Per
    RISE - Research Institutes of Sweden, Swerea, Swerea IVF.
    Concepts for simulation based value stream mapping2009Conference paper (Refereed)
  • 43.
    Solding, Petter
    et al.
    RISE, Swerea, Swerea SWECAST.
    Petku, D.
    Vestas Guldsmedshyttan AB.
    Mardan, N.
    Linköping University.
    Using simulation for more sustainable production systems: methodologies and case studies2009In: International Journal of Sustainable Engineering, ISSN 1939-7038, E-ISSN 1939-7046, Vol. 2, no 2, p. 111-122Article in journal (Refereed)
  • 44.
    Svenningsson, Roger
    et al.
    RISE, Swerea, Swerea SWECAST.
    Svensson, H.
    Volvo Group Trucks Technology.
    Borgström, Henrik
    RISE, Swerea, Swerea SWECAST.
    Gotte, Anders
    RISE, Swerea, Swerea SWECAST.
    Influence of the surface roughness on the fatigue properties in ausferritic ductile irons (ADI)2014Conference paper (Refereed)
  • 45.
    Svensson, Anders
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Paramonova, Svetlana
    Linköpings University, Sweden.
    An analytical model for identifying and addressing energy efficiency improvement opportunities in industrial production systems – Model development and testing experiences from Sweden2017In: Journal of Cleaner Production, ISSN 0959-6526, E-ISSN 1879-1786, Vol. 142, no 4, p. 2407-2422Article in journal (Refereed)
    Abstract [en]

    Improved energy efficiency is one of the most effective strategies for achieving energy sustainability and independence locally, regionally and globally. Industry accounts for 40% of global energy usage each year, which suggests its potentially significant impact on overall energy use. The rapid development of standards for more efficient equipment and components are pushing manufacturers towards further improvements on a component level. However, it has been shown that the largest efficiency potential is actually found in higher system levels in which components serve, such as production processes, ventilation or hydraulic systems. Even though the importance of increasing energy efficiency at a systemic level has been widely acknowledged in recent years, practical approaches are seldom discussed in the literature. This gap between aspiration and achievement calls for the development of new approaches to foster system efficiency in industrial systems. This paper presents a systems analysis and corresponding model to increase the energy efficiency of industrial processes that involve intensive usage of electric motor systems. The model originates from traditional value stream mapping. Three case studies representing three different industrial processes were conducted to develop and validate the model. In total, 31 energy efficiency measures were identified, 29 of which address actions beyond component levels. Alongside identifications of energy efficiency measures, the model promotes the creation of conditions for cross-functional worker participation. By applying this model, the knowledge and skills gained by industrial personnel working with improved energy efficiency, maintenance and production processes can be used immediately to generate improvement suggestions. The paper concludes that this model, based on a simplified energy-focused value stream mapping, could broaden the scope of energy efficiency actions, engage a larger group of workers within the organisation and increase systems efficiency. This can be further used as a practical tool for finding continuous improvement possibilities that will result in strengthened competitiveness and more cost-effective and sustainable manufacturing.

  • 46.
    Svensson, Henrik
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Sjögren, Torsten
    SP Technical Research Institute of Sweden.
    The effect of cooling rate, section size and alloying on matrix structure formation in pearlitic grey cast iron2011Conference paper (Refereed)
  • 47.
    Tiroler, Zoltan
    RISE, Swerea, Swerea SWECAST.
    Sweden's only female fettler?2008In: Foundry Trade Journal, ISSN 0015-9042, Vol. 181, no 3652, p. 46-Article in journal (Refereed)
  • 48.
    Wänerholm, Martin
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Klimatpåverkan av gjutgods2016Report (Other academic)
    Abstract [en]

    Swerea SWECAST was commissioned by the Swedish Foundry Association toupdate the background report for the carbon footprint indicator which was first putforward in 2011.The aim of the work was to analyze the emission of CO2 for thirteen foundryproducing countries when producing one tonne of cast product transported to aprospective buyer in Sweden.The Swedish Environmental Research Institute, IVL, has on Swerea SWECASTmission produced a report with general data on carbon dioxide emissions fromelectricity consumption and transport of goods from thirteen countries that have ormay have a significant role in the Swedish castings supply.Based on the background data presented by IVL and assumptions, calculationshave been made for a number of different metals. The results are an indication thatthere are climatic differences depending on the country the cast components ismanufactured in. In essence, it is the countries' electricity mix that controls the Swerea SWECAST AB Rapport nr 2016-003_outcome, where Sweden is very well, because electricity from hydro and nuclearpower produce low emissions of greenhouse gases in the operating phase.A risk with this kind of work is that the result is taken as income for not workingwith energy efficiency in the Swedish foundries. So should not the results beinterpreted. If foundries in other countries or individual foundries are working tostreamline its process and the Swedish foundries don’t there is the risk that theSwedish foundries after all end up behind.

  • 49.
    Wänerholm, Martin
    et al.
    RISE - Research Institutes of Sweden, Swerea, Swerea SWECAST.
    Heintz, Ida
    Minskat metallspill: Effektivare resursutnyttjande hos gjuterier och plåtindustri2016Report (Other academic)
    Abstract [sv]

    Tanken med projektet Spill till guld har varit att utveckla en internettjänst där det finns möjlighet att försöka sälja sitt material till intresserade användare alternativt knyta kontakter som kan användas för att hitta nya idéer hur man tar hand om sina restprodukter och kanske förädlar dessa.

    I arbetspaket metall har olika metoder för att få avsättning för slagg och metallinnehållande stoft från gjuterier studerats. Dessutom har möjligheten att minska mängden plåtspill vid tillskärning utretts.

    Först studerades möjligheter att återta metallstoftet till den egna processen och vad det skulle innebära ekonomiskt och hur hanteringen skulle ske. De stoft som analyserades innehöll dock en del annat än bara metall, till exempel sandrester och det visade sig därför vara svårt att få ekonomi i att föra tillbaka till den egna smältugnen. Andra projekt som genomförts visar att stoft med högre metallhalt eller som innehåller lite mer värdefulla metaller kan vara mer lönsamt. Det är alltså viktigt att skaffa kunskap om de stoft man har. Om stoftet ska återföras måste man hantera stoftet på ett bra sätt så att det inte flyger i väg när det läggs i smältan. Ett bra sätt att få god hantering är genom brikettering.

    Nästa steg var att undersöka om gjuteriernas restprodukter kunde användas i en annan bransch. Det mest naturliga var då att titta på om järn- och stålindustrin kunde ha ett intresse. Även här kan konstateras att stoft innehållande sandrester inte är helt optimalt och att det är svårt att få ekonomi i detta. Att separera olika material ur ett stoft kan vara ett viktigt steg för att få bättre ekonomi i återvinningen.

    När det gäller slagg från gjuterier i allmänhet kan dessa ibland innehålla relativt höga halter av rent järn och kan då säljas som skrot direkt. Ett antal olika användningsområden för olika typer av slagg har studerats både inom järn- och stålindustrin men även på annat håll. Även här har det varit svårt att få ekonomi i återvinningen av slagg. Inom projektet har kontakt även tagits med värmeverk för att se om slagg från gjuterier skulle kunna förbättra förbränningen i deras sandbäddar. Detta ser lovande ut och vidare diskussioner förs.

    Gällande minskat spill i plåtbranschen har en fallstudie genomförts samt omvärldsbevakning vid två mässor. Fallstudien visade på potential att minska plåtspill vid tillskärning av plåtkomponenter med laserskärmaskin från formatplåt genom användning av nya smartare nestingprogram. Hur stora vinster som kan göras beror på flera faktorer som med vilken tidhorisont som produktionen planeras, geometrin på komponenterna samt hur modern utrustning som används.

  • 50.
    Zamani, M.
    et al.
    Jonkoping University.
    Seifeddine, Salem
    RISE, Swerea, Swerea SWECAST.
    Jarfors, A.E.W.
    Jonkoping University.
    Effects of microstructure and defects on tensile and fracture behaviour of a HPDC component: Potential properties and actual outcome of EN AC-44300 alloy2014Conference paper (Refereed)
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