Smart casting processes

The ongoing digitalization is transforming industry in a disruptive manner and production of products is no exception. Here, digital twins are increasingly used to analyze and optimize manufacturing processes based on a combination of measurements and mathematical models of varying complexity.
The talk will put the concept of digital twins into proper context with respect to manufacturing processes and both data-driven and model driven approaches will be discussed. The recent trend of incorporating advanced microscale characterization and modelling for prediction of macroscale behavior will also be illustrated by an example from casting.

This presentation will give examples from research projects at DTU Mechanical Engineering and some of our partner universities will be used to show how digital sensors and optical scanning can be used to monitor and analyze foundry processes.

We will show how online monitoring in combination with structured experiments can be used to make relatively simple models that are useful for controlling and predicting effects of process parameters on the production output. Furthermore, we will look at how 3D optical scanning can be used to analyze precision in the manufacturing process.

Integrated modeling of the casting process and the subsequent manufacturing steps is a growing field in the industry. This is particularly the case for cast and heat treated parts where stress analysis is used for process optimization to provide improved solutions in casting design and product quality.
This presentation will give recent examples with trends from the automotive industry and a small look into the background of the applied methods.

What are the main drivers for digitalizing and digiting metal? Mega trends surrounding the concept of sustainable development such as climate change, social responsibility and resource efficiency establish a market for better understanding and utilizing the value of materials. Our era of digitalization shows how the globally abundant material silicon contributes to expontential value increase of any aspect of our civilization’s businesses, behaviour and artefacts.

What if we look more closely at metal with the perspective of the endless capabilities of digitalization and digitization? What if we can trace any piece of metal? What if any piece of metal can be digitally active, like a sensor? What additional value would that provide? Is it even possible?

This presentation will show how we started to show that it is possible.