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Łukasiewicz Research Network – Foundry Research Institute

Established	1946 (1946)
Focus	Casting
Address	73 Zakopianska Street Lesser Poland Voivodeship, Kraków, Poland
Location	Kraków , Poland
Coordinates	50°1′13.257″N 19°55′50.442″E
Website	iod.krakow.pl

Foundry Research Institute (Polish Instytut Odlewnictwa) – from April 1, 2019, operating within the Łukasiewicz Research Network – is a Polish research institute established in 1946 with headquarters in Krakow, conducting scientific research and implementation activities for the foundry industry in Poland in the field of new foundry technologies, control and measuring instruments, and machines and devices. The Institute focuses its attention on the best efficiency measures to protect the natural environment, make the work in foundries less strenuous and save both materials and energy. From April 1, 2019, it forms part of the Łukasiewicz Research Network.

History

The Foundry Research Institute in Krakow was established on February 1, 1946, by the Central Board of the Metal Industry, as one of the first post-war research institutes in Poland. The first director was Professor Kazimierz Gierdziejewski. Initially, the headquarters of the Institute was located at Basztowa Street 6 and then on the Main Market Square. In the second half of 1948, the Institute was moved to post-industrial buildings in Borek Fałęcki, at Zakopiańska Street 73, which is its current location.

In the years 1946–1951, due to organizational transformations, the name of the Institute was changed from the Foundry Institute (1946–1950) to the Main Institute of Metallurgy and Foundry (1950–1951), and then, in 1951, to the Foundry Research Institute.

At that time, the objectives and directions of the Institute activity were established, including the development of new casting materials and melting technologies for ferrous and non-ferrous alloys, cooperation with engineers to get the best solutions in the technique of casting design, studies of molding, core and auxiliary materials and of sand casting technology, improvements in knocking out, cleaning and finishing of castings with control and testing of foundry materials, research works in the field of standardization, and scientific and technical information, and training of staff employed in domestic foundries. In the initial period of the Institute activity, the main focus was on the reconstruction and subsequent modernization of the domestic foundry industry. The Institute has developed many successful and original solutions in the field of new materials, foundry technologies, control and measuring instruments, and machines and equipment. Modern casting materials and technological solutions developed abroad (e.g. inoculated gray iron and ductile iron) were implemented on a large scale in domestic foundries.

On April 2, 1949, a pilot foundry and mechanical workshops were opened, which created for the Institute a new opportunity to conduct the technological research. In 1953, a new three-storey building (Technology Building) was commissioned for use, and in 1980 another building called the Laboratory and Technology Building.

Owing to the cooperation with UNIDO (UN), Foundry Research Institute has become an important training center for the foundry personnel from developing countries and participated in the construction and commissioning of foundries in such countries as Syria, Iraq, India and Jordan.

The Institute has successfully developed numerous modern solutions in the field of foundry technology and materials for which it was honored with the State Prize - the most prestigious award granted in 1951-1990 for outstanding achievements in the fields of science, technology, literature and art. The Prize was granted for the following achievements: implementation of inoculated iron (1951), development of silicon bronzes (1952), development of technology and production of ductile iron castings (1953), development of cost-saving non-ferrous metal alloys (1955), development and implementation in industry of hot blast cupola furnaces with radiation stack recuperators (1964), implementation of CMS liquid self-hardening sands (1971), development of measuring instruments for testing of molding sands used in metal casting (1984). The systemic transformation, which started in Poland at the end of the 1980s, brought about a reduction in the Institute research staff and forced changes in the research and implementation works, closely linking this area of the Institute activity with the sources of financing.

In the years 1995–2005, the foundations of a modern Institute adapted to the principles of free market economy were laid. The research and technological laboratories were fully modernized. The following units were established: a rapid prototyping laboratory equipped with a LOM (Laminated Object Manufacturing) system and programs for simulation of solidification processes, a modern laboratory for studies of high-temperature phenomena in liquid metal-solid systems and Product Certification Office; statistical surveys of the Polish foundry industry were restored; a quality management system according to the PN-EN ISO 9001 standard was introduced, and research laboratories obtained accreditation. A Branch Contact Point was also established to assist the Institute staff in fund raising activity and implementation of EU research projects and structural projects.

Present day

At Foundry Research Institute, the research and development works are carried out by highly specialized and experienced scientific staff who implements the results of innovative studies using tools and devices of the latest generation as well as modern IT resources purchased thanks to co-financing from the European Regional Development Fund.

At present, the Institute operates three quality management systems confirmed by certificates and subject to continuous improvement – the integrated management system valid for the entire Institute, the management system in the Group of Research Laboratories and the management system in the Certification and Standardization Office.

Structural research projects implemented under the Innovative Economy Operational Program have proved to be particularly important for the development of the Institute, including the undertaking “Retrofitting the Research Infrastructure of the Małopolska Center for Innovative Technologies and Materials” (Innovative Institute – MCITiM), implemented in consortium with the Institute of Non-Ferrous Metals in Gliwice and its IMN Light Metals Division in Skawina, Aleksander Krupkowski Institute of Metallurgy and Materials Science, Polish Academy of Sciences, and the Institute of Advanced Manufacturing Technologies. Other projects of this type included: “Comprehensive informatization of the Foundry Research Institute through implementation of advanced IT applications and modernization of hardware and network infrastructure” (e-Institute) and “Advanced Materials and Technologies for Their Production” (ZAMAT), coordinated by the Institute of Non-Ferrous Metals in Gliwice, as well as projects such as “International patent protection of a method for the manufacture of precision castings”, “International patent protection of construction varieties of composite passive armor protection”, “Patent protection of ceramic layer composition for the manufacture of ceramic molds and products” and “International patent protection of a pressure reactor producing materials with oriented porosity”. A very important project implemented by the Institute for the European Space Agency (ESA) was the project “New generation lightweight materials for advanced space applications”.

Last years were the period of numerous investments and modernization of the Institute buildings. In 2009, the modernized part of the Laboratory and Technology Building with office and training rooms adapted to current needs was opened, and in 2011, the modernization of the premises of the lecture hall and research facilities was completed. In 2012, a comprehensive IT investment was launched under the name of the Scientific Database Center. In 2013, a parking lot was put into use, and a year later, modernization of the Group of Research Laboratories (ZLB) was completed. In 2015, a multifunctional measuring platform was purchased for testing the mechanical properties of solid materials and properties in nano- and micro-scale of coatings and layers. In the same year, a high resolution FEI Scios FEG scanning electron microscope was also purchased, and the necessary repair works on the technical infrastructure around the Laboratory and Technology Building (BLT) were completed. In 2018, the building of a specialized laboratory for materials testing was put into service.

The Institute became a laureate of the Pantheon of Polish Administration competition held under the honorary patronage of the Minister of Economy. The prize was awarded for the developed “Integrated Management System of the Foundry Research Institute”. Another prestigious award was granted to the Institute by the English-language monthly business magazine “Polish Market” and the Main Council of the Research Institutes during the “Pearls of Innovation – Progress 2013” competition in the Scientific Establishment category. The Institute won awards for outstanding services to support the economy and entrepreneurship during the 3rd edition of “Annual Business in Małopolska Meeting” and “Solid Company” competition in the Economic-Consumer Program under the patronage of a Representative of the European Commission. It also received the “Pyramid of Reliability” Honorable Mention and the Employee-Friendly Employer certificate awarded by the National Commission of NSZZ Solidarity Trade Union under the patronage of the President of the Republic of Poland Andrzej Duda.

On April 1, 2019, the Foundry Research Institute joined the Łukasiewicz Research Network – the third largest research organization in Europe http://lukasiewicz.gov.pl/ along with the Fraunhofer and Carnot research networks.

Pilot Plant

The history of Foundry Research Institute would not be complete without a reference to its Pilot Plant. The Pilot Plant of the Institute has contributed to the development of prototypes of machines and equipment used in the transport of molding materials, manufacture of molds and cores, knocking out of castings and sand reclamation, offering also a wide range of control and measuring instruments. The predecessor of the Pilot Plant was the Department of Training and Expert Studies and the Department of Experimental Workshops, both of which were separated from the Institute in 1951, obtaining the status of the Institute supporting units. The increasing demand for castings forced the establishment of several local divisions, such as the Bentonite Processing Plant in Sosnowiec-Milowice (1967); Local Group for the Manufacture of Control and Measuring Instruments in Wadowice (1968); Local Division in Bolesław working on the methods and means to improve the permanent mold casting process, and on the auxiliary materials and equipment for new foundry technologies (1969), Local Division in Końskie rendering assistance to foundries in the Kielce District and solving problems of technical progress in foundry industry (1970). In the 1980s, the Local Group in Wadowice producing control and measuring instruments was transformed into an independent “WADAP” Enterprise. In the period of 1991–1995, the majority of castings were made of high-alloy iron (Local Division in Bolesław), steel, inoculated gray iron and aluminum alloys (Pilot Plant in Krakow). In 1996, a new, ecological, investment foundry was put into operation in the adapted hall of the Laboratory and Technology Building, allowing for a considerable increase in the production of investment castings. In November 2000, the Local Division of the Pilot Plant in Bolesław was transformed into an INCAST Commercial Law Company with 100% participation of the Foundry Research Institute. After obtaining the consent of the Minister of Economy and Labor and the Minister of State Treasury, on October 1, 2003, the SPECODLEW Enterprise of Foundry Innovation commenced its business activity. It was established by providing a contribution in kind, i.e. an organized part of the Foundry Research Institute – its Pilot Plant. All shares in the newly established Enterprise were the property of the Foundry Research Institute. On December 1, 2006, the Enterprise got a new majority investor. The new investor made a contribution in kind in the form of a business entity – the Radom Investment Foundry. This contribution has considerably raised the SPECODLEW capabilities of producing precision investment castings.

Structure

Foundry Research Institute is divided into seven main substantive departments, which include Center for High Temperature Studies, Design and Prototyping Center, Corrosion Testing and Research Center, Department of Non-Ferrous Alloys, Department of Ferrous Alloys, Department of Technology, and accredited Group of Research Laboratories, which includes Laboratory of Chemistry and Environmental Protection, Structure and Properties Research Laboratory, and Laboratory of Nondestructive Testing.

Scientific activity

Ongoing projects – https://iod.krakow.pl/projekty/realizowane/

• Innovative production line for the manufacture of die castings with significantly reduced porosity – Application Project
• Recycling of post-production waste of aluminum alloys based on continuous casting technology – TECHMATSTRATEG
• A new generation feed system for high-performance longwall complexes – Application Project
• The effect of plastic processing by Differential Speed Rolling combined with multi-variant heat treatment on structure and properties of Haynes 282 nickel-based superalloy – SONATA
• Technological conversion of nickel alloys operating under extreme conditions – TANGO
• Next generation materials and solid state devices for ultra-high temperature energy storage and conversion – HORIZON 2020 (FETOPEN)
• Development of the composition and technology of production of a new generation hybrid bentonite and of a mixture containing this bentonite – LIDER
• Development of innovative working elements of forest sector and biomass processing machines based on high energy technologies of surface modification of the top layer of cast elements – TECHMATSTRATEG
• Innovative mold coatings for cast nickel-based superalloys – M-Era Net
• Comprehensive long-term education for employees of the CLLEFEII Foundry – HORIZON 2020 (RAW MATERIALS – ETI)
• High-temperature studies of the effect of alloying additives on thermophysical properties of compacted graphite iron in liquid state and on its wettability and reactivity in contact with metal oxides – OPUS
• Development and implementation of innovative, unsinkable, ceramic foam filters designed for filtration of Al alloys to facilitate the recycling of scrap metal – Smart Growth Operational Program
• Influence of tantalum content controlled by constant Al / Ti quotients on the distribution of alloying elements, morphology of precipitates and mechanical properties of model IN740-based superalloys after multistage heat treatment – PRELUDIUM.

Projects completed – https://iod.krakow.pl/projekty/zakonczone-projekty/

• SIC-WIN: Reactivity of Silicon-alloy/C-material system: Wetting versus Infiltration – POLONEZ
• Application of 3D optical digitalization, thermal imaging and tomography to evaluate the technological quality of wax pattern sets and multilayer ceramic molds used in the precision casting process of critical parts for aircraft engines – Applied Research Program
• Development mechanism of thermodynamically stable, thin and protective oxide scales formation at high temperatures in pure water steam on the alloys based on Fe and Ni structures with high chromium content – SONATA
• Reducing silver consumption in lead-free soldering – TANGO
• Analysis of phase transformations accompanying the decomposition of ausferrite in nickel-copper ADI manufactured under the conditions of cyclic ausferrite transformation – OPUS
• Development of an innovative and ecological process of metallurgical refining of cast iron in a casting mold reactor – INNOTECH
• Studies of the erosion and corrosion resistance mechanism in composite coatings based on carbides with additions of metallic particles – OPUS
• High-temperature studies of the phenomenon of liquid immiscibility in Gd-Ti-X alloys (X-Co, Zr) and reactivity in contact with oxide ceramics – HARMONIA
• The effect of nickel addition to aluminum on the evolution of structure and properties of the Al/ZrB2 phase boundaries – SONATA
• Development and implementation of technology for sealing bronze castings of industrial fittings operating under extreme conditions (pressure, sea water) – Targeted Project
• Patent protection of ceramic layer composition for the manufacture of ceramic molds and products – Innovative Economy Operational Program
• International patent protection of a pressure reactor producing materials with oriented porosity – Innovative Economy Operational Program
• Modern, graphene-containing composites based on copper and silver for the energy and electronics industries – GRAMCOM – GRAFTECH
• Information-decision system supporting the production of ADI – LIDER
• Innovative technology of producing cemented carbides for geotechnical tools – INNOTECH
• Composite carbide coatings to protect the surface of industrial crystallizers – INNOTECH
• A comprehensive system of mobility support for people with physical disabilities based on the Auto Mobility Center (AMC-2) – INNOTECH
• Innovative technology of producing forging ingots of different weights using versatile casting sets – INNOTECH
• Development of an innovative technology to produce large-volume rolls with increased operational durability – Applied Research Program
• The use of innovative technological and material solutions in the construction of wheelchairs – DEMONSTRATOR
• Additional modular armor of wheeled armored personnel carriers and tracked platforms – The Project on National Security and Defense
• New generation lightweight materials for advanced space applications 2013–2018 – ESA
• A family of specialist vehicles to carry out renovation and protection operations in the wet and muddy environment – DEMONSTRATOR
• Development of modern, economically effective technology and launching the production of high quality castings for machining tool holders – Targeted Project
• Development and implementation of a new design of the sealing-return system in a type series of cast iron check valves meeting the requirements of the PN-EN standard – Targeted Project
• Development of technology and launching the production of a new type of high-quality ceramic materials designed for precision investment molds and castings – Targeted Project
• Development and production implementation of a series of wedge gate valves with PE stub pipes for gas pipelines made of PE – Targeted Project
• International patent protection of a method for the manufacture of precision castings – Innovative Economy Operational Program
• International patent protection of construction varieties of composite passive armor protection – Innovative Economy Operational Program
• Innovative ceramic-carbon filters for molten metal alloys filtration – INNOTECH
• Development of innovative technologies for the manufacture of intricate, high-precision investment castings from light metal alloys – Applied Research Program
• Innovative feed system for a mining machine increasing the efficiency of mining and work safety in longwall systems – Applied Research Program
• Development of light steel castings for efficient aircraft engines – FP7
• Launching the production of high quality s.g. iron castings for the railway industry – Targeted Project
• Development of physicochemical and technological foundations of the titanium alloy casting process – Own Research Project
• The effect of micro-jet cooling during quenching on structure and properties of selected alloys. Experimental and simulation studies – Own Research Project
• Development of design and technology to make a hydroactive suspension system used in mobile unmanned vehicles resistant to IED type threat – Development Project
• Determining the impact of technological process on the quality of castings made from nickel superalloys for power, chemical and automotive industries – NICKEL
• The start up of production of ferrous alloy castings designed for operation under extra harsh conditions of abrasive and corrosive wear and tear to replace forged and welded structures – EUREKA E!
• Development of conceptualization solutions and access to knowledge components on foundry technologies in the context of innovation and production process improvement – International Member of Consortium
• Conditions for the manufacture of cast iron with thixotropic structure by the method of an inclined cooling plate – Own Research Project
• Comprehensive informatization of the Foundry Research Institute through implementation of advanced IT applications and modernization of hardware and network infrastructure – Innovative Economy Operational Program
• Studies and development of modern technology of the cast materials resistant to thermal fatigue – Innovative Economy Operational Program
• Improving the reliability of lead-free solder joints in electronic packages – Innovative Economy Operational Program
• Advanced materials and technologies for their production – Innovative Economy Operational Program.

Education and training

The Institute offers internships, work placements and diploma apprenticeships to university students, during which they have the opportunity to participate in the daily work of research teams and carry out commissioned tasks under the supervision of experienced engineers. Scientific internships are also held for the staff of universities and research institutes both Polish and foreign. The Institute organizes “open days”, during which visitors can get acquainted with the problems of casting technology and latest achievements in this field by watching the operation of modern research stands and devices. One of the attractions available to those who visit the Institute is an interactive exhibition “Casting is clear!”. The Institute also participates in regular events organized in Krakow, such as the Małopolska Innovation Fair or the Podgórze Open Doors Days. Since the very beginning of its activity, Foundry Research Institute has been conducting open and closed training workshops for industry representatives to enable them to constantly improve their skills and professional qualifications (http://szkolenia.iod.krakow.pl/).

Conferences

The Institute organizes numerous conferences, symposia and scientific seminars devoted to the problems of the widely understood art of making castings; periodical meetings are also held to summarize the work on project implementation.

Publications

Foundry Research Institute publishes scientific monographs, technical books, guides, albums promoting foundry, jubilee editions of research works (https://iod.krakow.pl/wydawnictwa-instytutu/) and the scientific and technical quarterly Transactions of the Foundry Research Institute (Polish Prace Instytutu Odlewnictwa) (www.prace.iod .krakow.pl). Some of the publications are available free of charge at the Digital dLibra Library of the Institute (http://bc.iod.krakow.pl/dlibra).

Library

Operating since the very beginning of the Foundry Research Institute activity, the Technical Library boasts a rich collection of specialized books and a collection of Polish and foreign magazines in the field of foundry and other related fields, such as metallurgy and materials engineering. The Technical Library has a SINTE database, which is a bibliographic foundry database containing abstracts of over 40,000 articles published in foundry magazines (American, English, French, German, Czech, Slovenian, Russian, Ukrainian) as well as abstracts of congress proceedings and R&D works done by the staff of the Institute.

Awards, distinctions, patents

The most prestigious awards obtained by the Institute include the Officer's Cross of the Order of Invention awarded by the Supreme Commission of Decorations of the Kingdom of Belgium as well as medals obtained at the International Trade Fair of Inventions, Scientific Research and New Techniques BRUSSELS INNOVA, at Poznań Fairs, Kielce Trade Fairs METAL, International Warsaw Inventions Show (IWIS), the iENA International Fair of Ideas, Inventions and New Products in Nuremberg, International Inventions Fair – CONCOURS LEPINE, BIS – The British Invention Show in London, Kaohsiung International Invention and Design Expo (KIDE) in Taiwan, the International Exhibition of Innovation, Technical Patents and Inventions INVENT ARENA, and the Award of the Minister of Science and Higher Education for International Achievements in Innovation, 1st place in The Polish Product of the Future competition, The Silver Laurel of Innovation in the Stanisław Staszic National Contest organized by the Chief Technical Organization – Federation of Scientific and Technical Associations, 1st, 2nd and 3rd place in the International Metallographic Contest organized by the International Metallographic Society, Polish Smart Growth Award 2018, and TECHNICUS Distinction awarded to the Institute for its publishing activity by the Chief Technical Organization – Federation of Scientific and Technical Associations. The Institute has obtained 339 national patents, 92 foreign patents and 82 protective rights for utility models: http://patenty.iod.krakow.pl/.

Cooperation with industry

Implementation is an important part of the Foundry Research Institute activity. The main aim of this activity is to introduce modern, energy-saving and environment-friendly technologies into industry. At the Institute, projects are carried out by consortia of scientific and industrial organizations. The Institute also performs research works, prepares expert opinions commissioned directly by industrial partners in Poland and abroad, and issues conformity certificates.

International cooperation

Foundry Research Institute maintains extensive contacts with foreign institutes, universities and enterprises, is a valued partner in the field of scientific and technical exchange, and also in the implementation of joint scientific and research programs, such as EU Framework Programs, COST (European Cooperation in the Field of Scientific and Technical Research) or EUREKA programs. The Institute cooperates with over 50 renowned scientific, research and development institutions in various countries around the world.

Membership in organizations

The Institute is a member of the leading international foundry organizations such as CAEF – The European Foundry Association, AFS – American Foundry Society, WFO – World Foundrymen Organization, and EICF – European Investment Casters' Federation.

References

• Collective work: 65 Years of the Foundry Research Institute 1946–2011, Kraków: Instytut Odlewnictwa, 2011.
• Collective work: 70 Years of the Foundry Research Institute 2011–2016, Kraków: Instytut Odlewnictwa, 2016.
• Collective work: Report 2017. Krakow: Instytut Odlewnictwa, 2018.
• Collective work: Report 2018. Krakow: Instytut Odlewnictwa, 2019.