Field of Business Activity

Research, development and technology transfer in the general interest and to support the economy are central topics for us. While 20 years ago it was numerical simulation that contributed to a better understanding of the casting process, so that today castings can be manufactured with the highest complexity and accuracy, today topics such as 3D sand printing, digitalisation, artificial intelligence and climate neutrality dominate the research and further development of casting processes and casting alloys.

These technological trends in connection with social developments are the central content of the current research projects at the ÖGI.

As a joint research institute of the Austrian foundry industry, the ÖGI has always been a driving force when it came to introducing new methods, optimising and improving existing processes or developing new processes and casting materials.

Research and Development

The research projects are cooperative, nationally funded as well as EU-funded and industry-commissioned projects and strategic in-house research projects. The ÖGI thus has comprehensive know-how in structuring research ideas, supporting the application process, but also in implementation through professional project management.

The projects are carried out in close cooperation with small and large companies in the economy. We often work for our clients as their external research and development department. Our specialists cover a comprehensive field of expertise and interdisciplinary topics are dealt with, for which a broad network of research partners is available.

The research areas include:

  • Casting processes & casting materials
  • Simulation & Digitalisation
  • Metallic materials & material composites
  • Climate neutrality, lightweight construction & sustainability
  • Computed tomography, visualisation & data analysis

Material Testing and Characterisation

Comprehensive material testing and characterisation are the basis for the successful further development of manufacturing and casting processes as well as the research and improvement of casting alloys. But also for preventive quality assurance, initial sample testing as well as failure analysis, the following examination and testing options are carried out:

Destructive material testing
Static and dynamic testing at RT and elevated temperature

Non-destructive material testing
Computed tomography, X-ray testing, visual inspection, crack penetrant testing

Chemical analysis
Wet chemical as well as ICP and Leco

Microstructural characterisation
Macro and micro characterisation as well as micro and nano hardness testing

Determination of thermophysical material properties
Thermal conductivity, thermal expansion, specific heat capacity

Moulding material testing
Raw materials, organic and inorganic moulding sand and core sand mixtures

Numerical Simulation of Casting Processes

A casting process that is reliable for series production avoids unnecessary scrap, thus saving energy and resources and making a contribution to sustainable production.

The ÖGI provides support in the development of complex casting processes and uses software adapted to the problem (MAGMASOFT, FLOW-3D, ANSYS Workbench). In addition, a comprehensive internal database of thermophysical data is available or can be measured in the company’s own laboratory.

The interpretation of the results and advice on problem solving is provided by experienced specialists. With the specialised knowledge and extensive know-how of the employees, even complex casting processes (e.g. centrifugal, composite and continuous casting) can be mapped using physical models and simulation.

Ein seriensicherer Gießprozess vermeidet unnötigen Ausschuss, spart damit Energie und Ressourcen ein und liefert so einen Beitrag für eine nachhaltige Produktion.

Das ÖGI unterstützt bei der Entwicklung komplexer Gießprozesse und setzt dafür eine der Problemstellung angepasste Software (MAGMASOFT, FLOW-3D, ANSYS Workbench) ein. Zudem steht eine umfassende interne Datenbank von thermophysikalischen Daten zur Verfügung bzw. können diese im eigenen Labor gemessen werden.

Die Interpretation der Ergebnisse und Beratung zur Problemlösung erfolgt durch erfahrene Spezialisten. Mit dem Spezialwissen und umfangreichen Know-how der Mitarbeiter können auch komplexe Gießprozesse (z. B. Schleuder-, Verbund- und Strangguss) mittels physikalischer Modelle und Simulation abgebildet werden. 

Quality Assessment and Failure Analysis

Basic process and material knowledge as well as research-based knowledge are necessary to carry out and evaluate the quality of castings and initial sample tests according to the state of the art. For this purpose, suitable destructive and non-destructive testing and examination methods, with proprietary evaluation algorithms, are used. The results of the ÖGI, as a neutral and independent body, serve both to improve quality and to define the quality criteria between the foundry and the casting user.

If technical components fail, it is absolutely necessary to determine the cause of the failure in order to prevent further failures or repeated occurrence.

For this purpose, a systematic and methodical analysis is carried out using the appropriate methods, from visual inspection to examination under a scanning electron microscope.

The decisive factors are often influences from production and manufacturing, design defects, an incorrect choice of material or material errors, incorrect dimensioning or unexpected stresses in the ongoing operation of the component.

Extensive knowledge, many years of experience and a detective’s instinct are necessary to track down the mechanical, corrosive, thermal or combination-induced cases of failure. The staff at the ÖGI have all these qualities at their disposal.

Surface-, Bonding- and Coating Technology

Within the framework of research projects on the subject of surface, joining and coating technology, we deal with the following topics:

  • Characterisation, testing and modification of metallic and non-metallic surfaces and coatings

  • Production, characterisation and optimisation of multi-material composites

  • Influence of process agents on the production process and the component surface (e.g. mould release agents, coatings and binders)

  • Advice on adhesive selection, construction and design as well as adhesive and component testing

  • Ageing and life cycle analysis, quality control and failure analysis

  • Load, corrosion and resistance tests against environmental and media influences incl. accelerated ageing

Technology Transfer

It is our mission and target as a non-profit institute, but also our aspiration and incentive, to make the know-how and knowledge acquired in research projects available to the general public and in particular to the economy through targeted technology and knowledge transfer.

This is done in the form of specialised training courses, publication of research results in specialist journals, publication of an annual report with brief information on the research projects and presentations at national and international conferences and congresses.
Furthermore, the Austrian Foundry Congress is organised annually and the research activities and results are presented.

In addition, there is technology transfer through “brains”, with well-trained staff moving to the industry.