+ ENERGY CONSUMPTION IN THE SYSTEM Project and research leaders

Eva Troell Swerea IVF Peter Nayström Swerea Swecast Lars Nyborg Chalmers Magnus Widfeldt Swerea IVF (red)

Content

1. Executive summary................................................................................................... 3 2. Background ............................................................................................................... 4 3. Objective .................................................................................................................... 5 4. Project realization..................................................................................................... 5 4.1 Sustainable heat treatment factories............................................................................... 5 4.2 Sustainable casting production....................................................................................... 7 4.3 Sustainable machine shops – Fluids and Waste Management ..................................... 11 5. Results and deliverables ......................................................................................... 14 6. Dissemination and publications............................................................................. 15 6.1 Knowledge and results dissemination.......................................................................... 15 6.2 Publications.................................................................................................................. 16 6.3 Collaboration to other projects..................................................................................... 16 7. Conclusions and future research ........................................................................... 17 8. Participating parties ............................................................................................... 17 FFI in short

FFI is a partnership between the Swedish government and automotive industry for joint funding of research, innovation and development concentrating on Climate & Environment and Safety. FFI has R&D activities worth approx. €100 million per year, of which half is governmental funding. The background to the investment is that development within road transportation and Swedish automotive industry has big impact for growth. FFI will contribute to the following main goals: Reducing the environmental impact of transport, reducing the number killed and injured in traffic and Strengthening international competitiveness. Currently there are five collaboration

programs: Vehicle Development, Transport Efficiency, Vehicle and Traffic Safety, Energy & Environment and Sustainable Production Technology. For more information: www.vinnova.se/ffi

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1. Executive summary The project ”Sustainable Production Processes” was executed from 2009 to 2012, within

the FFI partnership between the Swedish government and the automotive industry, specifically within the collaboration program Sustainable Production Technology, Vinnova project no 2009-00315. Three specific work packages have been executed:

Work packages: Work package leaders: 1. Sustainable heat treatment factories Eva Troell, Swerea IVF 2. Sustainable casting production Peter Nayström, Swerea SWECAST 3. Sustainable machine shops Lars Nyborg, Chalmers

Project leader was initially Tero Stjernstoft, former Swerea IVF now Vinnova, and then Magnus Widfeldt, Swerea IVF.

Work package 1: Sustainable heat treatment factories

Objective: To minimise energy consumption and the use of chemicals and consumables during heat treatment, specifically during cleaning processes.

Results: Key-index values for different heat treatment processes. The energy needed per tonne heat treated materials is particularly related to the percentage used of the furnace cavity. The case hardening process needed three times more energy per tonne if the owen was filled to 10% compared to a fully loaded owen. Heat treatment neeeds clean material surfaces, and environmentally adapted cleaning is a key process.

Laboratory processes as well as procedures that can be suitable for application in connection to the heat treatment workshop have been evaluated regarding surface cleanliness after washing, prior the heat treatment process. Methods for evaluation and measurement of surface cleanliness have been examined. There is still need for research regarding how clean a surface needs to be depending on heat treatment process to be applied, e.g. nitriding or case carburizing. Knowledge transfer has taken place by the Swedish Heat Treatment Centre (Värmebehandlingscentrum) and Värmebehandlingsforum.

Work package 2: Sustainable casting production

Objective: To develop more cost-efficient casting production and make progress towards “the waste-free foundry” by reducing or eliminating the amount of foundry-generated waste, using waste as a resource in other processes, and reducing the need for virgin materials in the production of castings.

Results: Increased internal reuse of sand is possible due to improved cleaning methods. Bentonite-bound green sand containing coal dust has been recycled for production of cores. Two different recycling methods have been tested – mechanical and thermal. The results

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