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Manufacturing of structural parts by HPDC Technology
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Ana Fernández-Calvo
IK4-AZTERLAN
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting.
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 2
� Problems with Conventional HPDC.
� Successful factors for structural HPDC
� Democratization opportunities of Structural parts by HPDC
2
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting.
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 3
� Problems with Conventional HPDC.
� Successful factors for structural HPDC
� Democratization opportunities of Structural parts by HPDC
3
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Structural HPDC
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 44
Source: Ducker Worlwide 2011
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
� Audi A8 was the first car in incorporating structural HPDC in 1994.
� The four generation of Audi A8 has an special Tailor-made cast part designin the Spaceframe architecture.
� The new structural HPDC manufacturing technology takes the key rolewithin the lightweight strategy of Audi for 2020.
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 55Source: Audi
within the lightweight strategy of Audi for 2020.
The four generation of Audi A8
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 6
Source: BDW 6
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
NewStructural
The needs of Structural parts are:
� High elongation to withstand impacts
� High yield Strength and/or ultimate Strength
� Heat Treatability
� Weldability
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 7Source: Structural HPDC: Rheinfelden catalogue AlSi10MnMg alloy
Structural HPDC
� Weldability
7
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting .
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 8
� Problems with Conventional HPDC.
� Successful factors for structural HPDC
� Democratization opportunities of Structural parts by HPDC
8
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� High rates of production at low cost
� Net – shape manufacturing process. Little or no machining.
� Production of complex shapes with close tolerances
� Thin walls (typical 1 – 5 mm)
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 9
� Thin walls (typical 1 – 5 mm)
� Excellent surface finish
� Integrated fastening elements → Significant cost and labor reduction.
� Quick, efficient and economical process.
� “Skin” effect can give very good fatigue performance
� Traditionally, it is not used to produce very large products like car doorframe.
9
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(Conventional High Pressure
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 10
Die casting)
10Source: TALAT. Internet available.
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
MeltingCleaningFiltering
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 11
IntensificationFillingPouring
11
Solidification Opening EjectionLubrication
+Die Cooling
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting.
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 12
� Problems with Conventional HPDC .
� Successful factors for structural HPDC
� Democratization opportunities of Structural parts by HPDC
12
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(Porosity ∼∼∼∼ 1 - 5 %)Main limitation
POROSITY
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 13
Solidification
shrinkageGas
entrapment
Air
entrapment
Gases from
lubricant
decomposition
Gas dissolved
in the alloy
13
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Other limitations
MicrostructuralVery limited Very limited
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 14
Microstructural
Defects Inherent
to HPDC
Very limited
weldabilityVery limited
heat treatability
Cold drop BlisterInternal porosity appears when welding
Delamination
14
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
NewStructural
The needs of Structural parts are:
� High elongation to withstand impacts
� High yield Strength and/or ultimate Strength
� Heat Treatability
� Weldability
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 15
Source: Conventional HPDC properties: European Norm 1706Structural HPDC: Rheinfelden catalogue AlSi10MnMg alloy
Conventional HPDC
Structural HPDC
� Weldability
15
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting.
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 16
� Problems with Conventional HPDC.
� Successful factors for structural HPDC
� Democratization opportunities of Structural parts by HPDC
16
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Fluxing• Degassing• Si modification• Sludge Factor• Dross
• Numerical Simulation• Gating Design• Vacuum gating• Full Die design
Die Melt
It is not just to apply vacuum : it is a combination of technologies, know-howsand quality checks.
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 17
• Repeatability is the key• Monitor of shot key variables• Real time shot control system• Die cavity sensors• Monitor of vacuum level• Detecting leak and blockages
• Chemistry• Properties• Repeatability• Automatic application
Die Concept
Melt Treatment
Shot & Vacuum
Monitoring and Control
Die release
17
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Numerical Simulation• Gating Design• Vacuum gating• Full Die design
Die Concept
Improves
Porosity:
Air entrapment
Porosity:
Solidification
shrinkage
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 18
Conventional HPDCStructuralHPDC
18
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Fluxing• Degassing• Si modification• Sludge Factor• DrossMelt
Treatment Microstructural
Defects Inherent to
HPDC
Porosity:
Gas dissolved in the
alloy
Improves
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 19
Very similar to that of good quality permanent mold or sand cast part, exceptthat TiB2 grain refinement is not necessary due to the high solidification rate.
� Degassing (H2 removal from the melt). Fluxing.
� Primary alloy (AlSi9MnMg alloy) + Sr modification.
� Die soldering criteria %Fe + %Mn > 0.7
� Sludge Factor criteria
SF = %Fe + 2⋅%Mn+ 3⋅%Cr < 2.2
Sludge particles
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Repeatability is the key• Monitor of shot key variables• Real time shot control system• Die cavity sensors• Monitor of vacuum level• Detecting leak and blockages
Shot & Vacuum
Monitoring and Control
Porosity:
Air entrapment
Reduces
Porosity:
Solidification
shrinkage
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 20
35 mbar80-100 mbar
200-400 mbar
20
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Repeatability is the key• Monitor of shot key variables• Real time shot control system• Die cavity sensors• Monitor of vacuum level• Detecting leak and blockages
Shot & Vacuum
Monitoring and Control
Porosity:
Air entrapment
Reduces
Porosity:
Solidification
shrinkage
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 21
Chill Vent Vacuum exhaust valve 3D Chill Vent
Conventional Vacuum Metal activated or Higher flow rate withoutshot controlled valve increasing locking force
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Repeatability is the key• Monitor of shot key variables• Real time shot control system• Die cavity sensors• Monitor of vacuum level• Detecting leak and blockages
Shot & Vacuum
Monitoring and Control
Porosity:
Air entrapment
Reduces
Porosity:
Solidification
shrinkage
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 22Source: VDS 22
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Chemistry• Properties• Repeatability• Automatic application
Die release
Porosity:
Gas from lubricant
decomposition
Improves
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 2323
Source: Chem-Trend
Photographic comparison of three die lubricants during spraying onto die steel for a initial
temperature of the die steel of 180 ºC.
First lubrication
4th lubrication
There is a clearHOT SPOT
The HOT SPOTis cooled
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Effect of the heat treatment
As cast Conventional HPDC
Heat Treatment applied toConventional HPDC
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 24
Heat Treatment applied toConventional HPDC
As cast Conventional HPDC
Heat Treatment applied toVacuum assisted HPDC
24
Heat Treatment applied toVacuum assisted HPDC
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Effect on weldability:TIG and MIG Welding are generally possible in T6 & T7 heat treated parts.
Laser Welding is the most exigent technology in terms of casting quality, evenmore than T6 & T7 solutionizing. Very low gas contents (from the melt, from thefilling process and from the lubricants) can be tolerated.
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 25
Without Vacuum Conventional vacuum With high vacuum
Friction Stir Welding is an attractive alternative
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
• Fluxing• Degassing• Si modification• Sludge Factor• Dross
• Numerical Simulation• Gating Design• Vacuum gating• Full Die design
Die Melt
It is not just to apply vacuum : it is a combination of technologies, know-howsand quality checks.
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 26
• Repeatability is the key• Monitor of shot key variables• Real time shot control system• Die cavity sensors• Monitor of vacuum level• Detecting leak and blockages
• Chemistry• Properties• Repeatability• Automatic application
Die Concept
Melt Treatment
Shot & Vacuum
Monitoring and Control
Die release
26
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Structural aluminum high pressure diecastings are being used for� Replacing
• Heavier materials
• Steel/Al assemblies and stampings
• Higher cost materials and processes
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 27
� Welded asemblies
� Lower weight (thin walls)
• Increased fuel economy
� Performance increases
� Pressure tight hydraulics
� Significant machining cost reduction
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Successful case I: Pillar B
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 28
First: Pillar B required 8 welded partswith only small HPDC part
Next generation: Only One HPDC part.28
Source: Audi
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71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Oil pan requirements:� Ductility on the bottom part to support the stones impact (ductility > 5 %)
� Stiffness in the flange area (hardness > 70 HB)
Conventional Solution: Partial heat treatment in bottom area
New Vacuum HPDC solution: As-cast quality is enough. No Heat treatment.
The whole casting fulfils both requirements in as-cast state .
Successful case II: Oil pan
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 29
The whole casting fulfils both requirements in as-cast state .
Source: BDW 29
Conventionalsecondary
AlSi9Cu3Mg alloy
High ductile alloy: Primary AlSi9MnMg
alloy
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� Aluminium content in automotive → Experience inStructural Components
� Conventional High Pressure Die Casting.
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 30
� Problems with Conventional HPDC.
� Success factors for structural HPDC
� Democratization opportunities of Structuralparts by HPDC
30
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As every OEM has the need to reduce weight.
Is it possible to democratize this new technology for medium size car?
Yes, it is. The democratization of structural HPDC is the main objective of theFP7-Soundcast Project, by using:
� Medium-good vacuum 80-100 mbars, achieved with a vacuum pump adaptable to
71st World Foundry Congress. Bilbao 201471st World Foundry Congress. Bilbao 2014
Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 31
� Medium-good vacuum 80-100 mbars, achieved with a vacuum pump adaptable toconventional HPDC machines.
� Secondary alloy (cost reduction) with similar mechanical properties to primary highductile AlSi9MnMg alloy.
� New laser welding procedure able to weld this new secondary alloy.
Source: “FP7-SME-315506 – SOUNDCAST”: Vacuum-assisted high pressure die castingwith reduced porosity at low cost.
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PARTNERS
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Claves de Competitividad en la Industria del Aluminio13 de Marzo del 2013 3232