Manufacturers of heavy machinery such as cranes, drilling rigs and others are placing increasing demands on component sub-suppliers. These requirements relate primarily to improving the quality of workmanship, increasing the accuracy of shape and dimensions, extending the service life (execution of increased mechanical properties from materials), improving operational safety, shortening delivery times and improving the ecological aspects of manufacturing. In response to the growing demands, Krakodlew S.A. intends to carry out extensive research and development works aimed at placing on the market significantly improved products in the form of castings of dome and flat weights. These are also castings, for which demand has increased significantly in recent years, sales of weights in 2021 amounted to 14 640 Mg, and in 2022 already 19 227 Mg, i.e. the increase y/y amounted to over 30%. The applicant will develop a completely new positioning and stabilisation system for tower ballast components using the control of the crystallisation and cooling process of the casting to increase their shape and dimensional accuracy . During the research work, a new system of moulding boxes called skeletal 3S will also be developed together with the LCA digital module, which will allow to reduce the time needed for solidification and cooling of castings by approx. 30%, will improve the casting geometry. Another innovation that the Applicant intends to introduce through the tests carried out is the innovative method of compacting the moulding mass ‘Vibrating membrane compaction of the moulding mass’, which will allow homogeneously compacting the mass (increasing the stiffness of the mould and reducing the deformation of the castings). Krakodlew S.A. as a result of the implementation of this project plans to file 3 patent applications. Implementation of the results of the project in the activities of the Applicant will have an impact on the development of the competitiveness and innovation of the Polish economy in the foundry sector on a global scale.
