The Progetto 2 mm was launched on December 1st of 2011 and from this date the different phases of the project development have begun:

1: ANALYSIS OF THE STATE OF THE ART

  •  Bibliographic research: bibliographic analysis of the technical scientific literature at international level, oriented to define the state of the art of gravity and low pressure casting of low thickness structural components of aluminium alloy.
  • Evaluation of the trends of academic and industrial research in the specific field of application in terms of innovative materials and non-traditional technologies through patent analysis on an international scale.
  • Analysis and evaluation of the current technological state: definition of the current state of the art for the production of thin-walled castings at the partners and the competitors companies existing in the European market. Collection of data and information relating to the fields of interest of each partner.
  • Comparative analysis of the castings produced with current technologies: comparative evaluation of the mechanical characteristics and defectological analysis of structural components derived from the current production obtained by the technologies of gravity casting, low pressure or die casting. 

2STUDY AND CHARACTERIZATION OF ALLOYS

  • Research and definition of optimal alloys and their characterization: UNIBS – Bibliographic, commercial and patent research of specific alloys for applications in the field of structural castings in low thickness mould. Identification of alloys potentially suitable for the use through the comparison with alloys currently used for the same applications.
  • Thermodynamic characterization of alloy samples through laboratory analysis and simulation.
  • Experimentation of new alloys through melting trials and laboratory analysis: melting tests in gravity casting with innovative alloys. Mechanical, metallurgical and defectological characterization of specimens casted separately and section samples taken from castings obtained from melting tests in traditional moulds according to current procedure. Comparative evaluation of the results relative to traditional materials. Definition of the geometry of specimens casted separately.
  • Analysis of economic feasibility: evaluation of the economic benefit of the production of new alloys through the use of new technologies in experimentation.

3PRODUCTION OF PROTOTYPE SYSTEMS

  • Chill castings for gravity - Study and realization of a plant monitoring and a regulation of process parameters: study and implementation of a system of supervision and control of a gravity casting machine which allows to monitor and optimize the casting process.
  • Machine which can be interfaced and managed by a management and regulation unit: realization of a machine for gravity casting interfaceable and manageable with the supervision system developed.
  • Low pressure castings - Study and realization of a casting plant with the application of vacuum: study of technical solutions for the vacuum implementation on a low pressure machine. Definition of a forecasting analytical model for the optimization of the vacuum implementation and control system. Construction of the low pressure casting machine with vacuum.
  • Installation, testing and development of the plants: installation and testing of the machines at the foundry; optimization of the control parameters and of the cycle times.
  • Analysis of the sensitivity on the process parameters through the simulation: development of a simulation campaign aiming to identify the influence of the process parameters on the product quality. Comparison with the results of the experimental campaign and implementation of corrective actions.