Materials and Manufacturing
Our research in the area of materials and manufacturing concerns material properties and manufacturing processes for cast materials.
The department of materials and manufacturing is a vibrant multidisciplinary research environment that advances the state of the art knowledge and fosters the development of highly skilled researchers and professionals.Our research focuses on material properties and manufacturing processes for cast components.
The work is based on the understanding and control of materials microstructures and mechanical and physical properties behavior. The purpose of our research is to develop knowledge about the relation between material composition, melt quality, process, geometry and defect formation as well as their relation to the mechanical and physical properties; from the materials design to the process to component in use. The research method is a holist approach to the full chain of component manufacturing: a synergetic approach includes alloy design, manufacturing process, post treatments, microstructure study, properties characterization, finishing treatments, and modelling of local performances with the final aim to implement the results into design tools. More information about the activities in the department can be found here.
The department cooperates with various national and international research institutions and industrial partners, and is engaged in basic and applied research projects. Coproduction with industrial partners is a strong characteristic of our project portfolio, both with large companies and SME. In this framework, the core research has 4 main directions.
Cast Iron is the most used metallic alloy for creating complex shaped items used in all industrial sectors (automotive, energy, communication, engineering). Cast Iron is also one of the few technical alloys recyclable 100% having a small footprint on our living environment and enable a full circular economy.
The research area is interdisciplinary and include all ferrous cast alloys with focus on lamellar, compacted, and nodular cast iron produced in both sand and permanent moulds. Phenomenon connected to the casting production process, such the mould and core making, liquid metallurgy, melt treatment, mould filling, interaction between the moulding material – mould atmosphere – molten metal, nucleation and inoculation, solidification and crystal growth, volume change, inter-dendritic flow and defect formation mechanisms are included in the research area.
An important activity in this research area is the study of morphology formation and its relation to final thermal and mechanical properties. Both static and dynamic tensile properties are covered.
Numerical modelling using deterministic approaches to predict material and defect formation as well the simulation of the casting process plays a central role in the research area. Importance is dedicated for thermal analyses aiming to connect observed phenomenon to thermal processes and predict casting properties in the production process as well to determine thermo-physical and thermo-mechanical properties as input for casting simulation.
Advances in this research area are strictly dependent on innovative own developed research instruments and a frequent experimental activity in foundry plants.
Aluminium and Light Alloys
The primary activity for the aluminium research is to pave the way to enable material descriptions and models to allow process simulation and use of local properties to be used both design and the process simulation for cast components.
The work focus on the use of both primary and secondary aluminium alloys to support a sustainable development of the foundry industry and the use of magnesium alloys. The work focus on the formation of the microstructure in existing and new casting processes. The description of the mechanical properties based on the microstructures are also part of the core activity. This relates to both thermos-physical properties as well as mechanical properties. The end game is to gather data and develop descriptions allowing for life-span prediction of the cast component in use. Imperative to the area is also the development of the actual casting process and tool development as these strongly influence the component properties and the industry must be prepared for this. Process development is thus also intimately coupled to the model development.
The research direction Surface technology deals with the surface properties of materials. Surface treatments for functional or aesthetical purpose are considered and optimized. Surface treatments are considered in different aspects, from the process parameters to the compatibility of the process and material to the substrate, from the pretreatment to the final characterization. Process parameters are linked to the surface microstructure and final surface properties. Corrosion resistance as well mechanical properties of the surface can be tested and tailored.
Special focus is given to electrochemical process of the surfaces, both in term of corrosion resistance of metals but also as protection treatments as anodizing and electroplating.
In the research direction Simulation Technology, research is conducted within topics as microstructure modelling, material characterization, casting process simulation, load analyses (FEM) and geometry optimization. These topics are all treated as a part of a closed chain of simulations for cast components, where different types of simulations on multiple scale levels can be utilized and combined. Examples of numerical techniques and simulations that are done include mathematical modelling of casting and solidification, casting process simulations, FE simulations of 2D and 3D microstructures as well as load analyses of cast components in use.
Find more information about the Simulation Technology research group here.