Kalle Jalava

As an assistant professor in the field of casting and forming methods, I deal with research and education related to how metals are shaped into usable components. In summary, my research interests include the whole manufacturing process of molded components, like design - tools - manufacturing methods - materials and metallurgy, a mixture of production engineering and materials science. 

• Sustainable and energy efficient processes for cast and molded product manufacturing
• Material property enhancement through metallurgy and processing
• Efficient material use through component design and shape optimization

My general areas of interest can be grouped as follows:

Tooling technologies and moldmaking

• Patternmaking for expendable mold methods - Ex: manufacturing aided with hybrid and additive technologies
• Expendable pattern methods - Ex: materials and hybrid production methods for investment casting/lost patterns
• Mold materials and new binder technologies for sandcasting methods - Ex: inorganic binder systems for ferrous casting use
• Patternless casting methods - Ex: utilization of 3D-printed sand molds

Materials - Metallurgy - Properties

• Ferrous cast materials, especially cast iron - Ex: optimization of cast iron properties for elevated temperature use
• Materials for tool/patternmaking purposes - Ex: suitability of additively manufactured polymers with foundry binders
• Non-ferrous cast materials
• Welding and joining of cast materials

Simulation - Design

• Casting simulation and method optimization
• Component design practices wrt. manufacturability
• Shape optimization methods - Ex:  cast component topology optimization wrt. manufacturability 
• Local material properties

Sustainable manufacturing themes

• Inorganic binder systems wrt. sand molds
• Melting and metallurgy of ferrous alloys
• Environmentally friendly tooling materials - efficient use of materials