Laboratory of Foundry and Device Design

Our activity

Laboratory of Foundry and Device Design specializes in research and development of advanced technologies for metal preparation in foundry processes.

Our research activities focus primarily on alloying, degassing, and the removal of non-metallic inclusions, as well as on evaluating the effectiveness of these processes. We also develop new light metal alloys, investigate their properties, and design dedicated casting technologies.

In addition, the laboratory carries out small-scale production of feedstock materials and semi-finished products, including ingots and billets made from aluminum and magnesium alloys.

We provide heat treatment services for aluminum alloy castings for external customers.

The laboratory also designs and manufactures prototype equipment, including ingot casting crystallizers, degassing units, and devices for monitoring and controlling metal gas content.

Offer

Our products and services

We specialize in the production of high-quality aluminum casting alloys and master alloys, supplied in the form of ingots and billets.

We are a manufacturer and distributor of:

alloying additives,
structure modifiers,
grain refiners,
master alloys.

We also provide heat treatment services for aluminum alloy castings and components.

In addition, we design and manufacture degassing units and industrial equipment for measuring and controlling the gas content of liquid metal.

Quality control and defects analyses

We are equipped with specialized instrumentation enabling:

assessment of liquid metal cleanliness – Prefil Footprinter®,
assessment of hydrogen content in liquid metal – ALSCAN™,
simulation and analysis of metallurgical processes – UMSA,
assessment of the degree of modification and grain refinement – TA100,
evaluation of the technological properties of liquid aluminum alloys – Metal Health compact die set.

Most of these tests can be carried out directly on the production line at the customer’s facility.

Quality control and defects analyses

Technological consulting

We offer technological support in the following areas:

Development of liquid metal preparation technologies, including aluminum recycling technologies in line with circular economy principles, removal of metallic and non-metallic impurities, alloy modification, and grain refinement.
Evaluation of the impact of technological parameters on metal quality and the final properties of semi-finished and finished products.
Continuous and semi-continuous casting of billets from light metal alloys.
Design and manufacturing of process line components.
Selection and configuration of foundry equipment.
Modernization of equipment and process lines.

R&D activity

Development of liquid metal preparation technologies, including feedstock selection, refining and filtration processes, alloy modification, grain refinement, and casting technologies for aluminum and magnesium alloys.
Evaluation of the influence of technological parameters on metal quality and the final properties of semi-finished and finished products.
Continuous and semi-continuous casting of billets made from light metal alloys.
Development of advanced material processing technologies, including methods based on rapid solidification.
Design and development of equipment and installations supporting foundry processes, in particular degassing units, crystallizers, and liquid metal distribution systems.

Equipment

Aluminum and magnesium melting furnaces
Production lines for aluminum and magnesium billets
Heat treatment facility for aluminum castings
Melt spinner station for the production of rapidly solidified materials
ALSCAN™ – device for measuring hydrogen content in liquid metal
Prefil Footprinter® – device for assessing liquid metal cleanliness
TA100 – thermal analysis system
Metal Health System – compact die set for evaluating the technological properties of aluminum alloys
UMSA – universal system for simulation and analysis of metallurgical processes