Structural
Structural Parts
Parts for
for Transportation
Transportation
Systems
Systems made
made from
from Aluminium
Aluminium
-
H. H. Kaufmann
Kaufmann 11 ;; A.
A. Mundl
Mundl 11 ,, P.J.
P.J. Uggowitzer
Uggowitzer 22
11 ARC
ARC Leichtmetallkompetenzzentrum
Leichtmetallkompetenzzentrum Ranshofen
Ranshofen GmbH
GmbH
22 ETH
ETH Zürich
Zürich
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Aluminium inin Automotive
Aluminium
Automotive Bodies
Bodies and
and Suspension
Suspension 2001
2001
(samples)
(samples)
Audi
Audi A2,
A2, A4,
A4, A6,
A6, A8
A8
BMW
BMW 3er,
3er, 5er,
5er, Z8,
Z8, Renault
Renault Aventime
Aventime
Honda
Honda 2000
2000
Porsche
Porsche Boxster,
Boxster, 911
911
Opel
Opel Corsa
Corsa
Lotus
Lotus Elise,
Elise, Opel
Opel Speedster,
Speedster, Ferrari
Ferrari 360
360 Modena
Modena
Mercedes CC--Klasse,
Mercedes
Klasse, SS--Klasse,
Klasse, Maybach,
Maybach, Rolls
Rolls Royce
Royce
Source: Auto Forum 1/2001
Lancia
Lancia Thesis,
Thesis, Alfa
Alfa GTV
GTV
Strong
Strong Engagement
Engagement of
of Al
Al--Producers
Producers
Alusuisse // Alcan,
Alusuisse
Alcan, Alcoa,
Alcoa, Norsk
Norsk Hydro,
Hydro, VAW,
VAW, AMAG,
AMAG, SAG
SAG
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Aluminium--intensive
Aluminium
intensive Audi
Audi A2
A2
Body Sheet
Body
Sheet Al
Al 6xxx;
6xxx; Extrusion
Extrusion Profiles
Profiles Al
Al 6xxx;
6xxx;
Vacuum Pressure
Vacuum
Pressure Die
Die Castings
Castings AlSiMg;
AlSiMg; AlMgSi
AlMgSi
3030 mm Laser
Laser Weldings,
Weldings, 1800
1800 Rivets
Rivets
Source: Aluminium Today 1/2/2000
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Body
Body inin Al
Al -- Sheet
Sheet Design
Design
Ford
Ford P2000
P2000
Hydroformed
Hydroformed Tank
Tank
Source: ATZ 12/2000
Alcan:
Alcan:
11
m² Steel
m²
Steel Sheet
Sheet
11
m² Al
m²
Al -- Sheet
Sheet
11
11
m² Polymer
m²
Polymer Sheet
Sheet
m² Mg
m²
Mg -- Sheet
Sheet
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
DMDM
7,75
7,75
DMDM 13,30
13,30
DMDM 17,90
17,90
DMDM 19,70
19,70
Casting
Casting Processes
Processes for
for Structural
Structural Parts
Parts
Gravity Casting
Gravity
Casting
Low Pressure
Low
Pressure Die
Die Casting
Casting
Vacuum High
Vacuum
High Pressure
Pressure Die
Die Casting
Casting
forged
forged Al
Al
Squeeze
Squeeze Casting
Casting
Thixocasting
Thixocasting
New Rheocasting
New
Rheocasting
Source: ATZ Sonderausgabe A4 11/2000
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Quality
Quality Requirements
Requirements toto cast
cast Structural
Structural Parts
Parts
low porosity
low
porosity
high ductility
high
ductility
heat treatable
heat
treatable
weldable
weldable
recyclable
recyclable
SAG
SAG -- Thixocasting
Thixocasting
low
low cost
cost
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Source: ATZ Sonderausgabe A4 11/2000
The
The New
New Rheocasting
Rheocasting -- Process
Process
melting
ladling
cooling
heating
filling
casting
New Rheocasting System
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
New Rheocasting
New
Rheocasting
NRC
NRC Slurry
Slurry maker
maker
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
New Rheocasting
New
Rheocasting
NRC
NRC Forming
Forming Process
Process
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Typical NRC
Typical
NRC Microstructure
Microstructure
AlSi7Mg,
AlSi7Mg, T6
T6
AlSi7Mg ++ 1515 %% SiC,
AlSi7Mg
SiC, T6
T6
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Typical Mechanical
Typical
Mechanical Properties
Properties
TT55 |
TT66 |
||||||
RR mm [[MMPPaa]] |
RR pp [[MMPPaa]] |
AA55 [[%%]] |
RR mm [[MMPPaa]] |
RR pp [[MMPPaa]] |
AA55 [[%%]] |
||
AAllSSii77MMgg |
119900 |
|
1144 |
||||
AAllSSii77MMgg ++ 00,,22 SScc |
|
44,,55 |
------ |
------ |
------ |
||
------ |
------ |
------ |
|
11,,11 |
|||
AAllSSii77MMgg ++ 1155%% SSiiCC MMaaggssiimmaall 5599 |
220000 |
------ |
------ |
------ |
|||
66008822 |
------ |
------ |
------ |
|
22,,55 |
||
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Influence of
Influence
of Volume
Volume Fraction
Fraction Solid,
Solid, VV ss ,,
onon the
the Mechanical
Mechanical Properties
Properties
AAllSSii77MMgg,, TT66,, 1100 mmmm SSttuuffee |
||||
VV ss [[%%]] |
00 |
3300 |
4400 |
5500 |
RR mm [[MMPPaa]] |
229933 |
229900 |
|
|
RR pp [[MMPPaa]] |
221100 |
221100 |
|
|
AA [[%%]] |
99,,99 |
1100,,55 |
1133,,88 |
1144,,00 |
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Influence of
Influence
of the
the Fraction
Fraction of
of Recycling
Recycling Scrap,
Scrap, VV RR ,,
onon the
the Mechanical
Mechanical Properties
Properties
AAllSSii77MMgg;; VV ss == 5500%% |
||||
VV RR [[%%]] |
00 |
2200 |
4400 |
6600 |
RR mm [[MMPPaa]] |
|
|
||
|
|
|||
RR pp [[MMPPaa]] AA [[%%]] |
1144,,00 |
1122,,00 |
1133,,55 |
1122,,55 |
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
NRC
NRC -- Welding
Welding Trials
Trials
Sample Positions
LKR -- Trial
LKR
Trial Part
Part
AlSi7Mg
AlSi7Mg
Laser
Laser- Hybrid
Hybrid Welding
Welding
Filler Material
Filler
Material AlSi5
AlSi5
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Microstructure and
Microstructure
and Properties
Properties after
after NRC
NRC -- Welding
Welding
Werkstoffkennwerte von Laser-Hybrid geschweißten NRC-Querlenkerproben, Werkstoff A356
300
15,0
Rm
Rp0,2
250
12,5
A5
223
224
220 214
212
210
200
10,0
153
155
148
150
144
148
150
7,5
100
5,0
50
2,5
2,2
2,2
1,5
1,6
1,8
1,6
0
0,0
Festigkeitswerte Rm; Rp0,2 [N/mm²]
Bruchdehnung A5 [%]
123456
Proben
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Accumulated Energy
Accumulated
Energy Consumption
Consumption (KEA)
(KEA)
KEA == KEAKEAKEA HH ++ KEAKEA NN ++ KEAKEA EE |
|||
Squeeze CastingSqueezeCasting |
New RheocastingNewRheocasting |
ThixocastingThixocasting |
|
KEAKEA |
11 |
1,021,02 |
1,951,95 |
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Cost Comparison
Cost
Comparison for
for Thixocasting
Thixocasting and
and NRC
NRC
100%
80%
60%
40%
20%
0%
Part Cost
Thixocasting
New Rheocasting (Primary Alloy)
New Rheocasting (Secondary Alloy)
1
Shift
3
Shift
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
Summary
Summary
•• Various
Various new
new cars
cars show
show high
high Al
Al--content
content inin body
body and
and suspension
suspension
•• Weight
Weight Saving
Saving 3030 -- 50%
50% compared
compared toto Steel
Steel or
or Cast
Cast Iron
Iron
•• Modern
Modern Casting
Casting Technologies
Technologies allow
allow complex
complex shapes
shapes
•• NRC
NRC isis aa new
new Process
Process for
for Structural
Structural Parts
Parts
•• Recycling
Recycling laws
laws are
are inin favor
favor of
of Al
Al and
and NRC
NRC
Source: Auto Forum 1/2001
Server:http://www.lkr.at E-Mail: office.lkr@arcs.ac.at
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