light metals market overview/ vehicle light … metals market overview/ vehicle light-weighting...
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Light Metals Market Overview/
Vehicle Light-Weighting Session
ARPA-E Metals Meeting
Detroit, MI - August 24-25, 2016
Steve Udvardy
NADCA
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Introduction
• What is NADCA?– Voice of the die casting industry and is committed to
promoting industry awareness, domestic growth in the
global marketplace and member exposure
– 7 full-time and 2 part-time people
• Profile
– Over 2,200 Individual & 235 Corporate Members
– Die casting employs 56,000
– Average sales of $165K per employee
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NADCA Activities
• Research & Technology Development
• Industry Marketing
• Meetings & Exposition
• Education
• Design Assistance & Standards
• Government Affairs
• Chapter Relations
• Technology Transfer
Information Dissemination-Communications-Networking
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End Market Use of Die Castings
• Automotive applications still drive the die casting market
• Home construction is an indicator as to where most of the
remaining markets are heading.
68% Automotive 32% Housing and Other
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Automotive Castings Driving Foundry Growth
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HPDC Growing, Other Methods Stagnant
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Longer Term Auto to Slow Rate of Growth
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7063.7
75.3 78.3
88.697.6
112
0
20
40
60
80
100
120
2007 2009 2011 2012 2014 2016 2025
World Motor Vehicle Production (million)
40% Growth in Automobile Production Worldwide
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Aluminum Content in Automotive
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Aluminum Content in Automotive
Source: Ducker Worldwide
/ CRU
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Die Castings in Vehicles Worldwide and
the U.S. Total Die Castings (2007-2025)
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Suspension arm in Magsimal®-59 in F temper in the Porsche
Cayenne, Audi Q7, VW Touareg
A Shift in U.S. HPDC is NecessaryStructural Die Castings
UTS: 194.31 Mpa
YS: 129.46 Mpa
%E: 14.12%
Actual Values
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Steel parts (10 parts) Aluminum – die casting (1 part) Integration of chassis components
Cadillac CTS RH/LH
Front Shock Towers
Aluminum design: 4.1 kg
Steel design: 10.4 kg
BMW X5/X6 RH/LH
Front Shock Towers
Aluminum design: 3.2 kg
Steel design: 8.2 kg
Tesla Model S RH/LH
Rear Shock Towers
Aluminum design: 2.7 kg
Steel design: 6.8 kg
Single Unitized Shock Towers
Jaguar
Structural Die Castings
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Door & window frames
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Structural Die Castings
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What We Need
• Low embedded energy low cost feed stock
• Flexibility in offering multiple alloys
• High strength high ductility alloys
• Thinner wall capability
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Where We’re At
• Low iron modifications for Al alloys
• On-demand melting
• Heat treatment of HPDC
• Modeling of flow distance
• Process definition for thin wall casting
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On-Demand Melting
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Heat Treatment
T5 Mechanical Properties
0.29% Mg
Cast Bars
Best T5:
4 Hrs at
355F/180C
Elong
UTS
Quality Index
0.2% YS
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T6* Mechanical Properties of Cast Bars
• Low-iron conventional die castings can provide an outstanding combination of strength and ductility
• Better than all Al-Si based sand castings
• Equivalent to best Al-Si based permanent mold castings
*-Short term salt bath solution treatment
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Alloy UTS (ksi) YS (ksi) % Elong.
A380 Standard 47.0 23.0 3.5
F380-T6 61.0 49.0 2.9
B360-T6 53.0 41.0 5.8
Heat Treatment
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DOD/DLA Thin Wall Al Project
• Previous version developed by Lindsey-Wallace assumed the
desired temperature at end of fill is liquidus temperature
• However, metal can still flow below the liquidus temperature
(ie. semi-solid casting)
Tgate = Tliquidus
Gate Spd = 1600
in/s
10 lb casting
1
s
g
m f
VA
v t
New Gating/Fill Time Equation
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Solution
where
, , ,s s
p p g p g
f gate s m gate s f gate s
c c A c Amx g T f v g T f t g T f
h P h P h P
&
ln
, 0 1,
ln,
1
liquidus die s liquidus solidus
gate die liquidus gate
sliquidus die s liquidus solidusf
gate s liquidus diep liquidus solidus
f
p liquid
T T f T T
T T T T
fT T f T TLg T f T Tc T T
L
c T
ln ,
1
solidus gate liquidus
liquidus die s liquidus solidus
liquidus gate
sgate dieus solidusliquidus solidus
T T TT T f T T
T TfT TT
T T
DOD/DLA Thin Wall Al Project
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Project kickoff on July 30, 2015 (2-year project)
Selected a baseline alloy (A380), a new die casting alloy (Alcoa EZCast), and LIFT380
Preparing for casting of specimens at OSU
Project kickoff meeting at LIFT
NADCA design for thin-wall Zn die casting
(to be resigned for Al in this project)
Alcoa specialty alloy for structural components
(to be evaluated and validated in this project)
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LIFT Thin Wall High Vac Al Project
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Summary
• NADCA has efforts focused on energy efficiency
and light-weighting
• NADCA assists with the development and
implementation of new technologies
• Member companies participate by conducting in-
plant trials on production equipment
• Cost points for new technologies to be adopted
by small business die casters <$100,000
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