1. Examples of
projects of
foundry unit

2. INDUSTRY REFERENCES
Boeing Airbus EADS Aernnova
Renault PSA Wolkswagen Honda
FIAT KYB Grupo Antolin Hispacold
CAF Irizar Cie Automotive Fagor
Enterprise Bravo INAUSA Nicolás Correa MTorres
Alcoa Aleastur J.L. French Ansola Befesa
Foseco Alumalsa Bostlan Dalphimetal
Env. Met. Alava Acciona Windpower Orbea Bicicletas Alcatel Espacio
ESA CMD Ferroli FIASA
Loramendi Mapsa Ronal Ibérica CESA
Sammic Air Liquide Praxair Tafime
Televes VALEO Schindler Dacia
Asturiana del Cinc Aurrenak I. Lebario Hydro
Grupo Abengoa Böhler uddeholm Comp. Vilanova Fiasa
Cemex Ferroli Hormesa Gis 2003
Insertec HUF España Guinea Hnos……………

3. The Division carries out R&D on technologies involved in the manufacturing and life cycle of a
product: material development & modification, design & engineering, manufacturing processes,
maintenance, after sale, disassembling, recycling and impact on the environment:
Modelling,
Modelling, Post- processing
Post- processing Disassembly //
Disassembly
Manufacturing
Manufacturing
Materials
Materials Design &
Design & &
& Recycling &
Recycling &
Process
Process
Engineering
Engineering Testing rigs
Testing rigs environment
environment
• Nanostructured & • Predictive • Metal casting • Surface Finishing • Selective
nanocomposite simulation. (Ferrous & Non- and cleaning. extraction of
materials. • Proc. modelling. ferrous alloys). • Coatings. materials from
• MMC & OMCs. • Design for weight • Steelmaking • Heat Treatments industrial waste.
• New alloys and reduction. • MMCs, plastic & • Cr, Cd free treatm. • Waste to energy
materials (e.g by • Ecodesign. OMC processing. & coat. valorization.
SHS) • Process & equip. • Cutting, Forming. • Integral • Recycling and
• High T materials. eng. (e.g. friction • Powder Metall. maintenance & valorization of end-
• Cellular materials. stir welding , • Welding & Joining. after sale service. of-life products.
• Coatings (thin, thermal spraying, • Surface Eng. (esp. • Advanced testing • Automatized
thick) & surface drilling & cutting, Thermal Spraying) rigs. disassembling.
treatments. pick & place, etc.) • Clean processing. •. . . . . . . . • .........
•. . . . . . . . . . . • .......... •. . . . . . . . .

4. REFERENCES for the European Project
European project that responds to the need of foundry sector
to seek solutions to the problem of the emission of dioxines ,
generated by the usual melting processes during casting of
ferrous metals.
Impact
•Reduction of the emission of diioxines.
Heating system for
casting laddles
Patent with priority date 23-
12-99 (“New casting furnace
for moulding”) led to a family
of patents granted in another
8 countries: USA, Russia,
Japan, Korea, France,
Germany, Great Britain and
Italy.
Sale in December 2007 of an
exclusive licence for
exploitation of the technology
to SERT-METAL (France).
Income of 6 to 9 Million € over
the next 10 years from
royalties for the sale of
installations.

5. REFERENCES for the European Project
The general objective of EDEFU project consists on investigating, developing
and to validate with prototypes on scale, new technologies of heating,
development of new materials to improve the heat insulations, new efficient
designs and innovating recovery systems of residues generated in the own
one make, so that they can allow the main consuming industries of energy,
the beginning of a new era of eco-efficient companies.
The ratification of the success of the project will be demonstrated through the
validation carried out with 4 demonstrators developed and implemented
using new technologies for the sector involved in the project: Foundry,
Glass, Cement and Ceramic. Quantified technical targets will reach
• 20% reduction in power consumption based on different process
assessments
• the null particle emission to the atmosphere through own integration in the
process
• the transformation of heat loses in other exploitable energies
• the reduction in at least 50% in the generation of wastes through innovating
recovery system of wastes of internal form
• and the reusability of the 100% of the generated CO

6. Main target of PLASMAPOUR: Energy Efficiency & Metallurgical Quality
Transfer ladle
POURING
MELTING
MELT COLD POUR HOT
PLASMA ACTION
To ensure correct
Less energy consumption Temperature adjusting metallurgical quality
Less oxidation at the right pouring To avoid defects linked the
Less refractory consumption
moment pouring temperatures

7. INDUSTRIAL INSTALLATIONS
LINGOTES ESPECIALES- Spain Plasma embedded on a tundish
Capacity 3 Ton.
Disk brake manufacturer Grey iron
Instalation: September 2010
Without plasma heater temperature
drop down 3°C per minute Refilling
With plasma heater temperature
stabilized

8. FUCHOSA- Spain Plasma embedded on a pressurized
furnace with inductor. (Hybride option)
Brake forks manufacturer Capacity 8 Ton.
Ductile iron
Instalation: September 2009
WITHOUT WITH PLASMA DIFFERENCE
Quantity of mold poured 4756 4335
% of mould poured at +/-3°C / set point 1.14% 62.00% + 60.86%
% of mould poured +/-5°C/ set point 9.89% 82.00% + 72.11%
% of mould poured +/-10°C/ set point 32.13% 97.00% + 64.88%
% of mould poured < - 10°C/ set point 73.00% 1.70% - 71.30%
% of mould poured > 10°C/ set point 2.80% 1.10% - 1.70%

9. MAGN 2008-2012
MAG N nesium ew Technological Opportunities
O
• Promote the Metal Sector in Spain through a
program of investment in high technology
• Get more knowledge and technologies on
metallurgy, processing and finishing of
magnesium
• Put Spain in the top of a futures market to
trend upward.
• Spanish Consortium to strengthen
competitiveness based on technology and
knowledge and strategy aligned with the
European R & D of seven framework. ECOFOND
• 18 industrial partners and 20 technological
centers and universities
• Budget: 32.000.000 € - Tecnalia: 5,000,000€

11. EQUIPMENT AND PILOT PLANTS
• Sand Casting and gravity casting
• High pressure Die Casting for aluminium and magnesium.
• Lost foam.
• Different melting furnace. Rotative, induction resistance
• New Rheocasting of aluminium and magnesium.
• Squeeze casting direct, investment casting, Plaster casting and centrifugal
casting
• Mould with sensors to gas, contact metal, etc.
• Simulation of process: PROCAST y SALSA.

12. FACILITIES: pilot plant
Sand Gravity MATERIALS: Aluminium
Lost foam Magnesium, Titaniun
Copper, zic, Steel, iron alloy
HPDC
Squeeze casting Direct
Thixocasting

13. FACILITIES: Laboratories
Mechanical characterization (universal Machines of test, creep, impact,
tests under cryogenic conditions, to room temperature and high
temperatures, dynamic, fatigue)

14. FACILITIES: Laboratories
Microstructural characterization (optical Microscopes, SEM, Image
analysis, EDS, WDS, EBSD, XPS, Auger, Gleebe 3800, etc.)
Chemical analysis, corrosion

15. REFERENCES for the Foundry INDUSTRY
CASTPRESS: a laboratory for pressure die casting in Tecnalia - Foundry
Instalations:
 Machine 950 Tn, melting and heating furnaces
for Al and Mg, automatic feeder, refrigeration
and lubrification systems and
 Semisolid processing machine (Thixo &
Rheocasting).
Type of research projects carried out:
 Life improvement of moulds and dies. (Investigating on diferent materials and treatments /
coatings and testing them in a special thermal fatigue testing machine.
 Study of process innefficiencies. Testing on moulds.
 R&D and testing of new non-ferrous alloys for pressure die casting to improve their
properties.
 R&D of new semi-solid technologies. (Development of proper alloys for the transformation of
material in a semisolid-state and development of new processes for the preparation and injection
of semi-solid materials).
 Improvement of machines and pressure die casting equipment.

16. OTHER EXAMPLES OF PROJECTS
DEVELOPED

17. REFERENCES for the Foundry INDUSTRY
CLOSED CELL METAL FOAMS
Production of components with foams
• Rectangular blocks
(200x80x80 mm3) of foamed
Al used for further production
of foam Al sandwich
structures made of an inner
foam core and an outer Al
dense skin (6 mm thickness)
by LPC technique.
• Injection parameters
controlled to avoid any
deformation of foam insert.
• Other technologies also
applied to produce these
sandwiches such as SC or
HPDC but the high pressures
involved in these
technologies can lead to foam
damage or even penetration
of molten aluminium in the
own inner foam structure.
Low Pressure die casting (LPDC) device for the production of aluminium foam sandwich
structures. On the left, the principle of the LPDC process is described. On the right hand side,
an industrial LPDC device together with a mould and a detail of a foam insert are shown

18. REFERENCES for the Foundry INDUSTRY
Alloying tablets
Industrial validation of Al
alloying tablets
Cylindrical alloying tablets of 90 mm diameter and
different heights according to different densities
and alloying metal contents in the composition
Tablets contain from 75% of alloying element, and
are usually available in units of 500 g or 1 Kg of
metal. The balance can be made up of pure
aluminium, non-hygroscopic sodium free flux, or a
mixture of both components.
The tablets are wrapped in plastic or aluminium
foil sleeves of 3 to 5 units packed into cardboard
boxes, each one containing usually 6 sleeves. Both
sleeves and boxes show the description of the
product, and they are colour coded for easing the
identification of the alloying element.
The company provides other alloying metals,
weights, sizes, packaging and/or specifications: Mn
Tablets, Cu, Fe, Ti, Cr, Ni.

19. REFERENCES for the Foundry INDUSTRY
Manufacturing of die pressure casting moulds by
“Stratoconception” and brazing
Process description
• Fabrication of moulds by stratification
and brazing.
• Optimized the brazing process without
high vacuum with  cost-saving.
• Validated the process under pressure
die casting and gravity casting with
repetitive results.

20. REFERENCES for the Foundry INDUSTRY
Design and optimization of automotive components
Need:
To adequate Al material and process to the
performance required, looking for the best properties.
Know how:
•Knowledge of processes (e.g. high P die casting,
gravity with sand and metallic mould, low P,
Thixocasting , Squeeze Casting, etc)
•Characterization , materials properties and
properties required to meet end-use industrial
specifications.
Results of the project:
•Technological mapping (material, process,
properties, end use applications)

21. REFERENCES for the Foundry INDUSTRY
Optimization and improvement of the Lock Screw
(design for aluminium)
Need
Traditional lock screws are made from spheroidal cast iron
and their design has changed little over the years.
OCAMICA Hnos, the company manufacturing the lock
screw, is collaborating with TECNALIA to develop a new
product with the sole limitation of the minimum resistance
it has to withstand. This product is widely used in
construction, workshops, etc.
Solution
After validation on the OCAMICA test benches, the product
was presented at several international trade fairs with
satisfactory results, allowing the client to penetrate new
markets.
All the production is currently sent to France, the United
Kingdom, Ireland, Norway, etc.

22. REFERENCES for the Foundry INDUSTRY
Development of an intelligent T control system for the mould .
NEED:
•Self-regulation of refrigeration and lubrification of high pressure die casting molds as a
function of internal and external T and automatic data saving.
•Important for moulding company, to obtain all information relative to performance of
mould.
KNOW – HOW & SOLUTION:
•Mold Design & simulation experience, know how in refrigeration and lubrication
systems and development of taylored control solutions
•Development of an intelligent management and control algorithm of the mold by a PLC.
Internal and
external
refrigeration
Infrared
measurement
Intelligent control Calculated output of
700
refrigeration times
600
500
400
Serie1
Tª
Serie2
300
Thermocouple
200
T Inputs PLC
100
measurement 0
0
4
3
7
2
6
0
5
9
3
2
6
5
9
4
8
8
8
1
8:5
8:5
8:5
9:0
9:0
9:1
9:1
9:2
9:2
9:2
9:3
9:3
9:4
9:4
9:5
9:5
9:5
0:0
0:0
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:4
9:5
9:5
Hora

23. REFERENCES for the Foundry INDUSTRY
CASTPRESS: Case 2 Project
Endurance of die casting mouls
NEED:
•Improve lifetime of molds in high pressure die casting.
KNOW – HOW:
•Materials and their behaviour under extreme conditions.
•Surface thermochemical treatments and coating technologies.
•Design and development of new testing concepts.
SOLUTION:
•Design and development of a thermal fatigue testing machine.
•Selection of best combination of material and surface treatment.
See
Video

24. REFERENCES for the Foundry INDUSTRY
CASTING of LIGHT MATERIALS: Aluminium and Mg
Target
Weight Reduction and High Performance
Technology
ALUMINIUM: Gravity Casting,
Investment/Lost Wax Casting , Lost Foam
(Sand / Magnetic moulding - Steel Shots),
HPDC, Squeeze Casting, Plaster Casting
MAGNESIUM: Gravity, Investment / lost
wax, Lost Foam (Sand), HPDC (Projects
Starting December 2008)
Application
s
ALUMINIUM: Know-
Products: Brake disk, Piston, Cylinder Head, How
Callyper Material development, characterization
MAGNESIUM: and process
(Projects Starting December 2008)
Products: Seat Frame, Steering Wheel,
Instrument panel carrier
2

25. REFERENCES for the Foundry INDUSTRY
CASTING: Al-MMCs (Aluminium Matrix Composites)
Need
Manufacturing prototypes of an automotive component
(brake drum) in a composite material and the fine
tuning of the different forming technologies: gravity
metal mould casting, sand mould casting and Squeeze
Casting.
These composites are known for their high wear
resistance, excellent mechanical properties at average
in-service temperatures and their heat conductivity.
Solution Brake drum
(Courtesy of Fagor Ederlan)
Comparison of the results of the metal mould and sand
mould techniques shows the former to be best: a
smaller grain size is achieved, as well as reduced
porosity, giving improved mechanical properties that
can be improved by subsequent heat treatment.
Specific industrial applications for automotive
components: brake discs and drums, clutch discs, Squeeze Casting Process
cylinders and pistons.

26. REFERENCES for the Foundry INDUSTRY
CASTING: Al-MMCs (Aluminium Matrix Composites)
Material:
Al/TiB2 composites produced by “in situ”
methods
Improvements:
Wear, Low CTE, lightness and mechanical
properties at high temperatures
Aplications:
Clutch discs, pistons and railway brake discs
2

27. REFERENCES for the Foundry INDUSTRY
CASTING: Al-MMCs (Aluminium Matrix Composites)
Material:
Al/Al2O3 and Al/SiCp Composites
Improvements:
Wear, Lightness, Low CTE and Mechanical
Properties at high temperatures LOCAL REINFORCEMENT
Aplications:
Clutch discs and ventilated brake discs

28. REFERENCES for the Foundry INDUSTRY
Chemical Conversion Coatings
Chromium free conversion coating
Patents: WO2008094193, EP1887105
F.J. Cano, U. Izagirre, O. Zubillaga, P. Santa Coloma, 13/02/2008
• Based on conducting polymers and zirconates.
• Aluminium alloys
SSF Tested panels
2024 T3 alloy – 336 hours
2

29. REFERENCES for the Foundry INDUSTRY
Anodising
Chromium free anodising based on nanoparticles and conducting polymers
Patent: PCT/ES 2008/000056
F. J. Cano, O. Zubillaga, G. Imbuluzketa, I. Azkarate
• Based on oxalic acid, conducting
polymers and nanoparticles.
• Aluminum alloys
Nanoparticles top layer: 150nm
Anodic oxide layer: 2.7 microns
TEM cross section
2

30. REFERENCES for the Foundry INDUSTRY
Thermal Spraying : Development of technology & equipment (3 of 3)
See
Video
Protection of Al moulds with wear &
corrosion resistant coatings
3

31. REFERENCES for the Foundry INDUSTRY
Permanent wear resistant coatings for die casting and low
pressure injection molding of Al parts (I)
Development of permanent or semi-permanent
coatings produced by PVD (Physical Vapour
Deposition), with a wear life significantly higher (min.
x 4-6 times) than traditional demoulding agents and
avoiding or minimising their problems.
Work consisted on:
•Study on compatible coatings with die casting molds
and dies able to improve performance of actual
solutions.
•Optimizing PVD processes for the present industrial
application.
•Establishment of procedures for its application on
moulds.
•Industrials tests with the new coatings.
•Cuantify the improvement and define possible
applications.
Coquilleuse équipée de deux outillages.
•These coatings shall improve availability and Outillage revêtu du dépôt Outillage revêtu de poteyages
productivity of moulds. PVD - CrAlN conventionnels.

32. REFERENCES for the Foundry INDUSTRY
Permanent wear resistant coatings for die casting and low
pressure injection molding of Al parts (II)
Ejection des grappes de coulée. Après 150 cycles, aspect du dépôt PVD-CrAlN sur la broche centrale.

33. Solid lubricant coatings on Al parts (by PVD Technology)
Novel solid lubricant coating based on MoS2 on Al pistons (2 stroke engine) to reduce
friction (under conditions of reduced oil-petrol mixture)  reduced friction and emissions.
• Reduction of oil content in petrol–oil mixture  reduced emisions
(from 1,5 to 0,3% oil reduction 15% reduction in hidrocarbons, 10% in CO, 10% in visible smoke)
• Solid lubrication in contacting surfaces to counteract loss of liquid lubrication.
• Hard wear resistant coating + outer solid lubricant, to extend wear life.
3

34. REFERENCES for the Foundry INDUSTRY
Example:
Production of Al powder from Al/plastic film waste
Aluminium / plastic film waste from discarded packaging (e.g. for food, cosmetics,
etc.) is transformed by means of a propietary process into two valuable products:
Aluminium powder and heat.
Aluminium powder:
•94-97% pure Al, 1% Fe residual
•150 – 500 µm powder size
Heat:
•By product gas as a result of
the combustion of plastic: with
Al coated plastic film waste
a calorific value of 7000 kcal/m2
(lower than natural gas 9000
kcal/m2)
Successful industrial trials carried out with: exothermic sleeves & Al tablets
3