Research Projects
The foundry industry in Germany has undergone a structural shift, and only foundries that can offer technologically sophisticated products of high quality will survive the tough international competition with the locational disadvantage of comparatively high energy prices.
Therefore, it is necessary to develop casting technology solutions that use the design freedom of casting to create products with an increased value.
Our concrete research goals in this context for the next few years are:
- the combination of hard and soft alloys in a single continuous casting process,
- material characterization and qualification with non-destructive residual stress analysis,
- environmentally friendly sand-binder systems for core packages or core-intensive permanent mold casting
Research Projects:
| Project Title | Person in Charge | Sponsors | Info |
FOCUS ON MOLDING MATERIALS | |||
Additive Manufacturing, Core Shooting, Multi-Scale Simulation, Environmental Sustainability | |||
| Core Shooter with Inorganic Molding Material System | Erwin Reberger, M.Sc. | Loramendi | |
| Design of Multilayer Sand Cores for High-Pressure Die Casting | Erwin Reberger, M.Sc. | DFG - 505145110 | |
FOCUS ON MATERIAL CHARACTERIZATION AND TOOL TECHNOLOGY | |||
Residual Stresses, Fibre Bragg Gratings, Microstructure Analysis, Neutron Diffractometry, Phase Transformation Kinetics | |||
| IDaP+: Integrated Data-based Process Chain Optimisation in Casting and Machining Production | Georg Fuchs, M.Sc. | cornet - AIF | |
| All4ADI: Extending the Range of Applications of Austempered Ductile Iron (ADI) | Christoph Weidner, M.Sc. | BMWK - 03EN2076B | |
| Hot-tearing detection using fiber bragg grating | Constantin Bauer, M.Sc. | DFG | |
FOCUS ON CONTINUOUS AND COMPOUND CASTING | |||
Ballistic 3D-Printing, Interface Analysis and Modeling, Process Chain Reduction | |||
| Functionally graded materials: continuous casting and forming of electrical copper conductors | Simon Kammerloher, M.Sc. | DFG - 504057701 | |
| Multi-metal Material Jetting with copper materials | Maximilian Plötz, M.Sc. | DFG - 524939160 | |
| Multi-Material-Injector-Casting MMIC | Maximilian Erber, M.Sc. | DFG - 501941276 | |
| Flat rolling of continuously cast Al/Cu composite strips with geometrically designed interfaces | Julika Hoyer, M.Sc. | DFG - 457434681 | |
| "Incremental Casting": Support Material and Close-Loop Control of Layer Height for Direct Metal Printing with Aluminum - Project Continuation | Benedikt Kirchebner, M.Sc. | DFG - 420547518 | |
COMPLETED PROJECTS | |||
| Sensor development for the measurement of operating and residual stresses | Constantin Bauer, M.Sc. | ZIM | |
| Additive processing of copper materials in the Material Jetting process | Maximilian Plötz, M.Sc. | AIF | |
| Deviation Compensation in Selective Laser Beam Melting - IDAM | Dr.-Ing. Christoph Hartmann | BMBF | |
| Casting Technology Approaches to Increase the Efficiency of Electric Motors | Georg Fuchs, M.Sc. Constantin Bauer, M.Sc. | DBU | |
| Development of a material model for gas generation in inorganic foundry sands | Simon Kammerloher, M.Sc. Benedikt Kirchebner, M.Sc. | DFG | |
| Development of a physical geometry analysis for process-oriented topology optimization | Maximilian Erber, M.Sc. | DFG | |
| "Incremental Casting": Support Material and Close-Loop Control of Layer Height for Direct Metal Printing with Aluminum | Benedikt Kirchebner, M.Sc. | DFG | |
| Analysis of Bonding Mechanisms in the Composite Casting of Iron-Based and Copper-Based Materials | Simon Kammerloher, M.Sc. | DFG | |
| Continuous Compound Casting of Cu-Al Semi-Finished Products | Thomas Greß, M.Sc. | DFG | |
| Compound Casting and Forming of Aluminum Materials | Tim Mittler, M.Sc., Thomas Greß, M.Sc. | DFG | |
| In-Situ Strain Measurement during Solidification of Aluminum Alloys using Fiber Optic Sensors | Florian Heilmeier, M.Sc. | DFG | |
| µ-Core II | Dr.Ing. Philipp Lechner | DFG | |
| Energy- and Material-Efficient Production of Copper Composite Semi-Finished Products using Composite Casting | Tim Mittler, M.Sc. Thomas Greß, M.Sc. | DBU | |
| Application of Ausferritic Cast Iron (ADI) for Dynamically Stressed Hydraulic Components | Martin Landesberger, M.Sc. | DFG | |
| Incremental Casting - the Generative, Droplet-Based Production of Aluminum Alloy Components | Dipl.-Ing. Benjamin Himmel | DFG | |
| µ-Core | Philipp Lechner, M.Sc. | DFG | |
| Production-Compatible Design of Gating Systems in High-Pressure Casting | Florian Heilmeier, M.Sc. | Bayerische Forschungsstiftung | |
| Opti Alloy | Dipl.-Ing. Georg Baumgartner | Bayerische Forschungsstiftung | |
| Casting and Characterization of Cu-Al Layered Composites | Dipl.-Ing. Manuel Pintore | DFG | |
| Thermal Management in High-Pressure Casting - Design of High-Pressure Casting Tools | Dipl.-Ing. Sven Jansen | INI.TUM / AUDI AG | |
| Continuous Composite Casting of Aluminum Materials | Tim Mittler, M.Sc. Dipl.-Ing. Manuel Pintore Dipl.-Ing. Martin Wimmer | FFG | |
| In-Situ Measurement of Deformation-Induced Martensite Formation in Ausferritic Cast Iron (ADI) | Dipl.-Ing. Patrick Saal | DFG | |
| Residual Stress Analysis using Neutron Diffraction | Dipl.-Ing. Matthias Reihle | DFG | |
| Core Shooter with Inorganic Molding Material System | Dr.-Ing. Benjamin Himmel | Loramendi | |
| 3D Printing with Inorganic Sand Binder Systems | Dipl.-Ing. Robert Ramakrishnan | DBU | |