Casting Top Models

Representing a value of about 2.7 billions NOK annually, aluminium casthouse products is of primary importance for the Norwegian industry and economy. In order to meet the emerging demands for more specialised products as well as requirements set by the i ncreased use of recycled alloys, a central element in Elkem's and Hydro's strategy is to integrate the use of advanced modelling tools into the process and product development. The central aspect is that the models relate controllable process parameters t o key quantities determining the process and final product quality, and thus systematise and make available to new "generations" the competence that has been developed over the years. Based on previous national and international projects Elkem and Hydro a re, together with IFE and SINTEF, already in the possession of quite advanced modelling tools. Faced against the near-future challenges, however; today's models are insufficient. Extensive scientific development is necessary for bringing the models to the level required for real breakthrough within process and product development; indeed models that are significantly different from those already existing are required. The scientific challenges reflect complicated, coupled phenomena within solidification p hysics, computational mechanics, and metallurgy. The project will lead to unique modelling tools that will enable Elkem and Hydro to carry out their future process and product development with the efficiency required to take the lead in new demanding mark et areas represented by automotive, aerospace, and building products. The project is co-funded by the foreign industrial companies Alcan (France) and Corus (The Netherlands), and an associated Eureka Project will be launched involving additional scientifi c institutions in France, The Netherlands, and Switzerland. As part of the Project, a PhD candidate will be educated at the University of Oslo.