Project – Innovations consortium – Ink development for improved casting

Revolutionary improvement of the casting process through the development of inks using sol-gel coating

Project start 1st April 2008. Expected completion 31st March 2011.

The Danish casting trade produces castings primarily using sandstone.
The essential drawback with this method is the resources used in rinsing and reparation of surface casting defects. The consortium’s objective is to develop water based resin mouldings, which guarantee a stronger, improved casting quality.
The resins are based on the most recent sol-gel technology, which allows different functions. As well as this, the resin penetrates further into the centre of the casting mould. This closes the pore layers in the sand material and prevents metal penetration eliminating surface casting defects.

Project Objectives

  • Develop resins to improve the casting process
  • Guarantee strong improved casting
  • Minimize work burdens on the casting foundries
  • Reduce environmental burdens of resins for sand forms.

Participants

  • Danmarks Tekniske Universitet        
  • Vald. Birn A/S                                       
  • Jernstøberiet DANIA A/S                    
  • MAN Diesel A/S                                     
  • Frese Metal- og Stålstøberi A/S            
  • Johan Jensen and Son                             
  • Nordsjællands Metalstøberi                 
  • Vestas Casting Group A/S                    
  • MAGMA Technologies A/S                  
  • C.C. Jensen                                                                  
  • DISA Industries A/S                             

Activities

  • Development of new sol-gel resins
  • Casting and test screening
  • Load analysis
  • Evaluating the timing of casting defects on cast items