| EU Life money for innovations in the core package system (CPS) at NEMAK Dillingen, Germany
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Since 2005 NEMAK Dillingen in Germany gets funds from the European Union in the EU LIFE program to develop a new environmental-friendly way to cast motor blocks in the Core Package System. |
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| Read more about how Nemak Dillingen managed to get EU funding and its successful run of the LIFE project.
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Nemak Dillingen´s objective was to develop an environmentally and technically effective process for the production of aluminum engine blocks.
This technique, using an inorganic binder, consumes 30 per cent less energy and reduce greenhouse gases emissions, deposits and waste water.
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| Nemak Dillingen successfully applied for the LIFE program, the EU’s biggest environmental funds and now receives almost 30 per cent of the project's total budget from the European Commission. |
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| How did Nemak Dillingen, the former Hydro Alucast and the EU find each other? |
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| The beginning of a beautiful partnership |
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| "While testing the inorganic binder technology, we were approached by the consultancy PNO, which suggested drafting a proposal to get EU funds from the LIFE program. We accepted PNO’s offer and won the project," said Joachim Kahn, project manager of the Inocast - LIFE project for Nemak Dillingen in Germany. |
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| "Hydro Aluminum’s R&D in Bonn, which had already participated in two EU projects in the framework of the 5th European Research Program, also shared with us some information on how to manage an EU funded project." |
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| The project |
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| "The project was running very well during the last 3 years and finished in march 2007. Over 300 Audi engine blocks were produced using the new techniques. We run a demonstration pilot line for the inorganic core production and casting technology and worked together with the customer Audi on a light weight sand casting engine block in hypereutectic alloy," says Mr Kahn. |
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| "In close contact with Nemak Linz we shared our know how in regular meetings and expert exchanges between the two companies" added Dr. Ingo Prass, process engineer. |
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| Regarding work with EU institutions, Mr Kahn says, the "cooperation with the Commission was running smoothly. We participated in a kick-off workshop with all German LIFE project managers in October 2005. In March 2006, we could already demonstrate the core production and casting." |
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| Worthwhile, but a lot of work |
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According to Mr Kahn, participation in EU projects is extremely interesting, but the additional communications work should not be underestimated.
"The support of the EU pushed our project internally and made many people interested. Talking to people outside the company and seeing our work from different sides, we learned a lot about our own work," concluded Mr Kahn.
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| Concerning project administration, he advises to check calls for proposals very carefully, especially reporting obligations, and to discuss everything with potential project partners.
In fact, "additional support for administration is very important, because you have enough to do to run your project."
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| Dr. Prass: “Due to the elimination of combustion of the organic binder a substantial reduction of emissions during casting and decoring process is achieved. This results in lower complexity for
exhaustion, air cleaning and post combustion of fumes in the total process line starting with the core shop, cast house, decoring, heat treatment and ending with the sand reclamation system.
The decoring process of inorganic core packages is in development with mechanical hammering and shaking techniques. For the sand reclamation a pilot line with core breaker, sand washer and sand dryer was developed to validate the feasibility of the sand recycling process.”
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| “To meet highest expectations in design and material properties of the aluminum engine block the CPS precision sand casting process offers the best possibilities.” Dr. Speicher points out and adds: “Casting hypereutectic alloys with local chills in critical areas like main bearings or bore surfaces will meet the demands on a light weight and high stressed component for future engines.”
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| EU
LIFE Project Data |
| Project-No.: |
LIFE05 ENV/D/000185 |
| Project-Name: |
Demonstration of environmentally friendly aluminium engine block Core Package Casting (CPS) using an inorganic binder
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| Reference period: |
from 16.01.2005 to 16.03.2007 |
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Download
Project Report |
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The feasibility of warm box core operation with inorganic binder was demonstrated with a pilot production cycle for an Audi four cylinder engine block.
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Project meeting at Nemak Dillingen demonstration plant
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I4 aluminium engine block in CPS with inorganic binder and section of inner oil drains
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