To compete in the international iron manufacturing market, the capability to efficiently produce large-scale casting parts while conserving resources is becoming increasingly essential. Particularly with wind power systems, the dross* found in large cast iron components with nodular graphite (GJS) can increase manufacturing, personnel and energy costs. These components must frequently be re-worked using extremely time-consuming manual processes.
Manufacturers of cast components (wind power turbines and ship engines for instance) are all too aware of the problem with dross, an issue that has not been resolved to date.
A research project involving renowned industry partners has finally opened up the possibility of examining large casting components with dross defects in a targeted fashion and developing ways to turn dross into usable parts, keep the re-work to a minimum and in particular avoid the scrapping of defective components, something which is a major benefit to manufacturers and users.
For more than 40 years, researchers at the Fraunhofer Institute for Nondestructive Testing IZFP have been involved in the development and enhancement of innovative nondestructive testing (NDT) methods for every conceivable industry.
Whether it`s cracks, delamination, material damage or material changes, these defects may frequently be invisible to the human eye, but not to the nondestructive testing experts at Fraunhofer IZFP. To date, the research industry has had little involvement in the problem of dross since these components are either re-worked or declared as rejects.
“Research has shown that several nondestructive testing processes possess excellent potential in more accurately identifying and characterizing these impurities. Our part in the unverDROSSen research project involves further developing existing NDT processes and where applicable to transfer newly developed processes into practical application,“ explains Dr. Jochen Kurz head of the Materials Characterization department at Fraunhofer IZFP. Working closely together with Fraunhofer IZFP is the Fraunhofer Institute for Structural Durability and System Reliability LBF, which is examining the issue of structural durability.
The unverDROSSen** project is being sponsored by the German Federal Ministry of Education and Research through its Jülich project management organization. Under the project leadership of Fraunhofer LBF and with the participation of renowned industry and association partners, the primary aim is to transfer the results of the research into practical applications for industry. The project is slated for completion by the end of 2017.
* Dross describes impurities caused by oxidation that form on the surface of molten metals. Components that exhibit these types of structural defects are frequently rejected during the construction of wind power Systems
** (a German word that means thorough, with painstaking care)
Sabine Poitevin-Burbes | Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP
Enhanced ball screw drive with increased lifetime through novel double nut design
23.01.2018 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH
Scientists from Hannover develop a novel lightweight production process
27.09.2017 | IPH - Institut für Integrierte Produktion Hannover gGmbH
Animal photoreceptors capture light with photopigments. Researchers from the University of Göttingen have now discovered that these photopigments fulfill an...
On 15 March, the AWI research aeroplane Polar 5 will depart for Greenland. Concentrating on the furthest northeast region of the island, an international team...
The world’s second-largest ice shelf was the destination for a Polarstern expedition that ended in Punta Arenas, Chile on 14th March 2018. Oceanographers from...
At the 2018 ILA Berlin Air Show from April 25–29, the Fraunhofer Institute for Laser Technology ILT is showcasing extreme high-speed Laser Material Deposition (EHLA): A video documents how for metal components that are highly loaded, EHLA has already proved itself as an alternative to hard chrome plating, which is now allowed only under special conditions.
When the EU restricted the use of hexavalent chromium compounds to special applications requiring authorization, the move prompted a rethink in the surface...
At the ILA Berlin, hall 4, booth 202, Fraunhofer FHR will present two radar sensors for navigation support of drones. The sensors are valuable components in the implementation of autonomous flying drones: they function as obstacle detectors to prevent collisions. Radar sensors also operate reliably in restricted visibility, e.g. in foggy or dusty conditions. Due to their ability to measure distances with high precision, the radar sensors can also be used as altimeters when other sources of information such as barometers or GPS are not available or cannot operate optimally.
Drones play an increasingly important role in the area of logistics and services. Well-known logistic companies place great hope in these compact, aerial...
16.03.2018 | Event News
13.03.2018 | Event News
08.03.2018 | Event News
19.03.2018 | Trade Fair News
19.03.2018 | Life Sciences
19.03.2018 | Life Sciences