Volvo's "Future Process for Castings" uses chemically bonded sand molds with a water-cooled steel chill to increase casting strength and dimensional stability while reducing environmental concerns. Since 1995, the Swedish auto mobile and heavy truck manufacturer Volvo has had its Powertrain foundry in Skovde working to develop new materials and processes that can meet the increasing demands of its diesel engine customers. Castings for this market are being pushed to the limits of their abilities in terms of structural strength as designers dramatically increase the combustion pressures in today's engines. In response, the foundry developed and brought online a new casting process, the Future Process for Castings (FPC), in late 1999 as a means to increase casting quality while reducing the environmental affects of sand casting. The new process required an 11.1 million dollars investment. With actual production begun in the Fall 2001, the foundry currently is using FPC to produce gray iron cylinder heads for some of Volvo's 9 and 12 liter engines. Total production for the process is currently 6000 tons/yr. "The long-range objective is to cast a greater number of components with this process, which will undoubtedly live up to its name" said Sven-Erik Dahlberg, head of development at Volvo Powertrain's foundry in Skovde, and the leader in the development of the patented process.
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