Resource efficient heat treatment of cast steel components with digital tools

Purpose and goal

Swedish steel foundries want to increase value creation in the heat treatment of castings by shortening process times and increasing flexibility with regard to costs, time, energy consumption and climate footprint. In this project, we will develop simulation models for optimization and control of a number of steel foundries´ heat treatment processes. We are thereby starting a digitization work intended to by-and-by replace local tradition and rules of thumb with more precise and systematic digitized methods to control these processes.

Expected effects and result

In the project, digital calculation and planning tools are developed based on physical principles that provide adequate scientifically based decision support. The digital tools being developed give foundries a whole new flexibility in the heat treatment process, when times, temperatures, furnace packing numbers and other parameters can be easily adjusted to achieve the desired quality outcome for a large number of products and alloys. After the completion of project, the digital tools are expected to be further developed to higher TRL levels and become new commercial products.

Planned approach and implementation

The project creates an overall picture of the entire heat treatment process technically, economically and organizationally. Heat treatment recipes are then formulated through finite element model (FEM) optimization of the furnaces and cast components. A digital planning tool is created for compression ratio, times, temperatures and other parameters for a fast and resource-efficient heat treatment process. In addition, development of methods for real-time control of the process begins.