WP’s Description

S/T Methodology and associated work plan The achievement of the above mentioned objectives is guaranteed by a proper S/T methodology, basically structured in 6 different Work Packages:

WP1- Specifications and Technical Coordination. This work package constitutes the first step of the system engineering which goal is to put in common and to cross knowledge and expectatives of all partners.It will includes the following tasks:

  • Partner needs inventory
  • Pooling the state of the art on equipment, software codes, sensors, data transmission, prognosis and proactive methods, guidelines and tools,
  • Defining application scenarios:
    • Pilot applications
    • Choice of technological solutions.
  • Consortium agreement..
  • Technical coordination.


WP2-New cast iron manufacturing cell. WP2 focuses in the design of the manufacturing system. WP2 and WP4, constitute the “technological part” of the project. WP2 will include the following tasks: T2.1-Improve energy efficiency of melting process (induction and plasma heating). T2.2-New pouring system (high performance and low resources consuming) T2.3- New and low cost nodularization treatment (magnesium vapor,…) T2.4- Intelligent flexible inoculation systems. This task will be focus in the following subjects: a) Dynamic-multiple inoculation, b) New anodic inoculation studies related with T2.1.

WP3-Artificial Intelligence-based control system This work package, along with WP 5, constitutes the “smart control” in this project. It will include the following tasks: T3.1 Real-Time Data Gattering (RTDG). T3.2 Statistical process Control System (SPC). T3.3 Case-based and Fuzzy Inductive Reasoning. T3.4 Holistic enabling technologies for cast iron quality validation (Differential thermal analysis, On-line microstructural analysis, and Internal sanity inspection (X-ray approach).

WP4- Automation based on robotics for foundry process improvement WP4 contains two tasks. It is focused on the automation based on robotics for foundry process improvement. It will include the following tasks:T4.1-We propose to develop an affordable system having the versatility to perform a automatic test samples pick-up cell. T4.2-The project aims to use robot system, which will almost totally eliminate the problems in fettling and finishing of castings made in batch quantities. The equipment will have the flexibility to carry out all of the four most important operations, fettling, studs grinding, flash removal and surface upgrading.

WP5-Simulation and optimization techniques for processes and equipment WP5 focuses in the development of computational methods for analysis and experimental validation. It will include the following tasks: T5.1 Thermo-fluid dynamic modelization (Melted metal flows simulation in cast iron processes and Casting process simulation). T5.2 Experimental validation and procedures (Similarity models, PIV methodology including Lab testing).

WP6-Demonstration The main task of WP6 is to construct the final demonstrators according to the specifications of WP2 and WP3 and WP4. It will demonstrate that the hybrid manufacturing strategy and concepts are applicable to the range of processes operated by the industrial consortium partners, minimum in one open access pilot facilities, mainly in Fundiciones de Roda. The main goal is to demonstrate a clear breakthrough using project developments in comparison to the state of the art solutions. It will include the following tasks: T6.1 -New cast iron manufacturing cell. This will include: induction/plasma furnace, enhanced pouring unit, Mg vapour injection device for nodulation process, -anode inoculation device, and multiple-dynamic inoculation equipment. All these demo-activities are related with WP2. Also, include: automatic test samples pick-up cell, differential thermal analysis, on-line microstructural analysis, and X-ray imaging 25 Flexicast 6 July 2012 25 equipment for on-line inspection. T6.2-Robot cell for deburring and grinding. The project aims at an easy to use robot system, which will almost totally eliminate the problems in fettling and finishing of castings made in batch quantities. The equipment will have the flexibility to carry out all of the four most important operations, fettling, studs grinding, flash removal and surface upgrading. The robot’s dual-armed manipulation reduces peripheral devices to a minimum. It integrates human-robot task cooperation during all operational phases (set-up, configuration, and production), recognition of objects, persons and environment connected to online re-planning of motions, and tasks.

WP7- Cast iron technolgy knowledge. Life cycle assessment. The goal of this WP which constitutes a permanent support activity of/for the project is to save and formalise knowledge and experience accumulated along the progress of the project. This should be done by: a) Permanent communication, b) Capitalise knowledge generated by design activity and the experience returns from using pilot applications. c) Formalising results of the project in guidelines and possible standards, contributing to building European standardisation in this field. It will include the following tasks: Experimental test benches and procedures. Standardization approach, and best practices rules and safety. On the other hand, life cycle assessment will be treated in order to have ways to measure the efficiency of the environmental aspects on a number of selected processed pieces (at least three pieces).

WP8- Exploitation plan, socio-economic aspects, and cost/benefit analysis. Dissemination and training. The exploitation activities will be worked in WP8. Dissemination and training activities will be implemented during the project duration. A plan for the exploitation of the new FLEXICAST manufacturing technology will be agreed by all partners in WP8. Also, it will include the following tasks: Guidelines, Dissemination and training activities and Pre-exploitation plan during the first 12 months.

WP9- Financial and administrative management It will be focused to assure the most appropriate financial and administrative management. Also a proper quality plan to control the quality of project results will be created. Because of the project potential impact is expected to have in many industrial domains, a detailed and credible exploitation plan and an effective and multimodal dissemination strategy will be created. Those permit an actual deployment of project results at different level, and the highest knowledge of project benefits. The project last 4 years and a preliminary GANTT project is reported. This permits to perceive the strong interdependence and complementarities among the different project phases.