Yield is the ratio of the weight of a cast component ready for delivery to the total weight of material used to fill the mold, including feed channels and risers, as well as other losses of liquid metal during casting.
Smart Yield encompasses the knowledge and technologies developed by AZTERLAN for high-performance casting, that is, production with the optimum ratio between the weight of the metal used and the weight of the finished component.
With a global vision of the casting process, Smart Yield developments are focused on:
- Metallurgical quality adjustment.
- Optimization of feeding systems, molds and risers.
- Development of a stable and robust production process.
- Implementation of predictive control and automation models for monitoring and ensuring the correct performance of the process.
- Reduction in the amount of metal used in the manufacture of components.
- Saving energy consumption.
- Reduction in consumables such as: sand, chimneys, inoculants...
- Reduction of waste and emissions.
- Assured metallurgical quality.
- Optimal melting conditions.
- Optimal and stable nodulizing treatment.
- Feeding systems adjusted to the specific characteristics of the metal and the geometry of the mold.
- Adjusted tools and equipment.
- Development of MPC and specific procedures for each production process.
- Implementation of control and monitoring procedures and tools at the plant.
0) Diagnosis and objectives
Global analysis of the process aimed at detecting the inefficiencies that affect the loss of yield performance.
Establishment of objectives and design of the action plan.
1) Ajusting molten-metal features
With the focus on conditioning and repeatability of the process, this phase focuses on ensuring the metallurgical quality and the optimal characteristics of the liquid metal (composition, viscosity, temperature, etc.), as well as on the definition of the optimal conditions of melting and pouring.
2) Tooling development
Development and implementation of new tooling concepts adjusted to the characteristics of the metal and the feeding needs of the parts.
Dimensioned risers and filling systems that favor self-feeding, optimization of the amount of pieces per mold.
3) Predictive Control Models
In each phase, the corresponding protocols are developed, identifying the optimal conditions for the process.
In the form of PCM and control algorithms, they are implemented in the casting process monitoring systems to ensure a correct performance and indicate corrective actions.
Modular implementation in the plant
Scaling of the developed solutions to the different production lines and/or production plants.
“The Foundry of the Future is that of connected processes that is able to take advantage of the knowledge generated inside the company at the same time that it keeps learning from its manufacturing and market experience.
Along with a deep knowledge of metallurgy, Industry 4.0 technologies, advanced data management systems and machine learning technologies have landed in this industry to transform the way castings are conceived”.
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