MDH researcher contributes to reduced CO2 emissions in the airline industry

May 27, 2015 | Research/Cooperation

Doctoral student Mohsin Raza at Mälardalen University (MDH) carries out research to develop more efficient casting methods, which makes thinner and lighter metal components possible. This can be the answer to increasing demand from the industry and contribute to reduced carbon dioxide emissions.


Higher requirements regarding lower costs, less fuel consumption and reduced emissions have caused ever increasing demands on lighter and more complex geometries, that is hard-to-form components, in industrial products. The airline industry in particular is interested in more thinly cast components. However, casting lighter components with thinner walls, but without inferior quality, is a challenge. It requires a very good understanding of the different steps in the casting process, and in particular of the final solidification process.
– Research on casting has been carried out since the 40s, but there is still a lot of work to be done until we understand the solidification process for components with thin walls, which is much more complicated, says Mohsin Raza, who defended his licentiate thesis on 22 May.

2 millimetres or less

In his licentiate thesis, Mohsin Raza investigates the casting of components that are thinner than two millimetres and how factors such as flow and temperature affect solidification during the casting process. His experiments have shown, among other things, that forms being filled from below result in a more stable casting process and higher filling levels in the cast products than top-filled forms. Complex components with organic forms, that is without right angles or edges, have proven to be sensitive to the solidification process. The research results provide a deeper insight into how different steps in the casting process affect the possibility to produce goods with thinner walls, and they have already been applied in a project at the company TPC Components AB.
– The aim is to reduce the weight of components in aircraft and industrial gas turbines, and also to contribute to the development of a strong Swedish supply chain for complex, thin-walled cast products. Lighter gas turbines would mean lower CO2 emissions, says Mohsin Raza.

Continues at MDH

Mohsin Raza took his engineering degree in Pakistan, where he also worked in the steel manufacturing industry, before he moved to Sweden for continued studies. He became interested in metal casting early on and saw the opportunity to do research within product development at MDH as a suitable next step and an exciting challenge. Mohsin Raza will continue his research at MDH, in cooperation with TPC Components AB, hoping that it will result in a doctoral thesis.
– We want to improve our prototypes in order to do more tests and will also investigate alternative ways of producing thin-walled cast goods, says Mohsin Raza.