october 2008 jürgen wüst - visi-trak · jürgen wüst october 2008 key figures bdw technologies...
TRANSCRIPT
![Page 1: October 2008 Jürgen Wüst - Visi-Trak · Jürgen Wüst October 2008 Key Figures BDW technologies GmbH Employees 323 Turnover 50 Mio. Euro in 2007 Production - 5.500 to / anno - 5](https://reader034.vdocument.in/reader034/viewer/2022052101/603aa02a77500e2184138560/html5/thumbnails/1.jpg)
October 2008 Jürgen Wüst
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October 2008 Jürgen Wüst
Innovative
Vacuum
High Pressure Diecasting Technology
High-Q-Cast™
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October 2008 Jürgen Wüst
Key Figures BDW technologies GmbH
Employees 323
Turnover 50 Mio. Euro in 2007
Production - 5.500 to / anno
- 5 Mio. parts / anno - Ca. 100 different products
in Aluminium Vacuum
High-Pressure-Diecasting
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October 2008 Jürgen Wüst
Know-how in High-Integrity Die Castings
1997 AUDI A2 24 parts, first supplier in high volume series production
2004 AUDI A8 Takeover of 8 parts from a competitor (+GF+)
2003 BMW X5 Development project Changing to Aural-2 by BMW
2004 Jaguar XK Development and series production of 12 parts
2004 Proton MSX Development project with mit LOTUS 12 parts
2004 AUDI TT Development and series production of 4 parts
2005 GM Safe Development project with GM and Contech, USA
2007 Daimler Current development partner for several projects
Magna Steyr
Porsche
Audi
Alloy AURAL-2® and heat treatment AURALTHERM®
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October 2008 Jürgen Wüst
Trapped gases -
(high magnification)
Typical Die Casting Defects
Shot from scanning electron microscope (SEM)
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October 2008 Jürgen Wüst
Areas indicating a
material separation
(Oxide)
Typical Die Casting Defects
Shot from scanning electron microscope (SEM)
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October 2008 Jürgen Wüst
Typical Die Casting Defects
Areas containing
shrinkage porosity
Magnification: 150 x
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October 2008 Jürgen Wüst
High-Q-Cast™
Standard
Vacuum
Diecasting
Standard
Diecasting
0 % 0.16 % 0.4 % 1 % 2.5 % Density Index DI
Gas Porosity inside Die Castings
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October 2008 Jürgen Wüst
Die
Concept
Gating
system
Simulation
Melt Treatment
DCM- Shot End
Sure-Trak2 Shot Control
Vacuum
Die Release
Chemistry
Die Release
Application
Humidity
Monitoring
CCC-
Monitoring
High-Q-Cast™
Shot Sleeve
Lubrication System
Vacuum Die Casting Process Technology
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October 2008 Jürgen Wüst
Aural Alloys:
Special alloys have been developed to meet mechanical
properties of new applications
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October 2008 Jürgen Wüst
Part
Design
Material
Data
Simulation
Software
Process
-Parameter
Defect Prediction
• Thermical Stresses
• Incomplete Die Fill • Soldering • Trapped Gases • Shrinkage Porosity
• Distortion
Optimization
• Gate Desin
• Part Design
• Process Conditions
Numerical Simulation
for Die Fill and
Solidification
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October 2008 Jürgen Wüst
Process Analysis – Solidification
(Shrinkage Porosity)
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October 2008 Jürgen Wüst
Process Control – Die Temperature
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October 2008 Jürgen Wüst
Process Analysis – Die Fill (Gas Porosity)
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October 2008 Jürgen Wüst
Gate Calculation
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October 2008 Jürgen Wüst
Melt Treatment
Periodic Chemistry Check De-gassing
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October 2008 Jürgen Wüst
Sure-Trak2™ Shot Control System
Produce Precise and Repeatable Injection Control
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October 2008 Jürgen Wüst
A special shot sleeve lubricant application system has been developed to minimize
contamination of the cast part
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October 2008 Jürgen Wüst
High-Q-Cast™ Control Unit - Main Screen
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October 2008 Jürgen Wüst
High-Q-Cast™ Control Unit - Limit Set Point Screen
0.5 PSI
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October 2008 Jürgen Wüst
Components – Vacuum Line
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October 2008 Jürgen Wüst
Components – Coarse / Dust Filter
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October 2008 Jürgen Wüst
Components – Solenoid Valve
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October 2008 Jürgen Wüst
Components – Hydraulic Control Unit
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October 2008 Jürgen Wüst
Components – Vacuum Valve Activator
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October 2008 Jürgen Wüst
Components – Vacuum Die Valve
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October 2008 Jürgen Wüst
BDW has selected
some die release
chemistry that is
effective in minimizing
contamination of the
casting
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October 2008 Jürgen Wüst
Humidity Monitoring
Computer Controlled
Casting Software
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October 2008 Jürgen Wüst
Aural-2®
AlSi10MgMnFe
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October 2008 Jürgen Wüst
Chemical Analysis (wt. %) Si: 10 %
Mg: 0.3 % Mn: 0.5 %
Fe: 0.18 % Ti + Sr
Alloy AURAL-2 (AlSi10MgMnFe) Auraltherm
grey: quaternary AlFeMnSi phase
Which properties are related to the single alloying elements? Si: castability, (mould filling, solidification shrinkage, etc.)
Mg (+ Si): strength
Mn + Fe: avoid sticking to the die Fe: crack initiation, corrosion behaviour
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October 2008 Jürgen Wüst
Property Potential of AURAL-2
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October 2008 Jürgen Wüst
Compression
test with
Aural-2 cast
structures
No cracks in the deformation zones!
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October 2008 Jürgen Wüst
Compression test with Aural-2 cast structures
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October 2008 Jürgen Wüst
Three High-Q-Cast
Castings:
•Heat treated & MIG
welded together form this
component from the front
area
A-pillar
Strut dome
Upper and lower longitudinal member
AUDI A2:
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October 2008 Jürgen Wüst
A-Pillar inner
right
A-Pillar outer
right
A-Pillar outer
left
A-Pillar inner
left
Requirements:
Yield > 120 MPa Tensile > 180 Mpa
Elongation > 15 % True to size
Weldability
Corrosion Resistance
Alloy: GD-AlSi10MnMg (AURAL-2®)
Heat Treatment: AURALTHERM® Source: Audi AG
Example: High Integrity Die Castings (Audi TT)
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October 2008 Jürgen Wüst
Audi A2
Product development: Shock
Tower Prototypes Pilot-series
casted at BDW technologies.
Technology transfer for serial
production and support to
CONTECH, Clarksville, TN.
Development and Technology Transfer: Shocktower BMW X5
AURAL-2®
AURALTHERM®
Yield > 120 MPa
Tensile > 180 Mpa Elongation > 15 %
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October 2008 Jürgen Wüst
Lift
Solution Treatment
Aging
Cooling
Loading Area
Insp
ection
/
Un
load
ing A
rea
Lift
1st Floor
2nd Floor
Heat Treatment Racks
• max. number of Racks: 120
• Processing Time: 140 min.
Air
Quenching
Continuous Heat Treatment Line „Auraltherm™“
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October 2008 Jürgen Wüst
cooling rate
465 460 450
Temp Ref.
Lines.
Solution treat hold on solution
temp. 460°C
±5K / > 60 min.
hold in annealing
furnace 223°C
including heating-up
±5K / 120 - 160 min.
Temp. [°C]
time
Process with tolerance
860° F
430° F
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October 2008 Jürgen Wüst
Side beam (6)
1
2
3
46
5
Cross member (1)
Longitudinal beam (2)
Control arm (3)
Strut dome (4)
Rear axe cross member (5)
Porsche suspension parts in Aural-alloy
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October 2008 Jürgen Wüst
Aural-5™: (AlSi7MgMnFe) [%] :
Si Mn Fe Mg Ti Sr
6,8 – 7,2 0,5 – 0,6 0,18 – 0,2 0,34 – 0,38 0,04 – 0,08 140 – 180 ppm
0 2 4 8 6
1000
1100
1200
1300
10 12 14 16 18 20
Silicon-Weight- %
Te
mp
era
ture
, °F
577°C
11.7%
Liquid
S + (Al) S + (Si)
+ Eutectic ( + )
+ Eutectic ( + )
100 % Eutectic
ca. 60 % Eutectic
1.65%
Al (100%)
Aural-5™
Chemical Composition
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October 2008 Jürgen Wüst
Ductile Oilpan
Requirements (without Heat Treatment)
• Flange Hardness : 70 HB
• Elongation (Bottom) : 8 %
• Stone-Chipping Resistance : 65 pound force - foot
• Leak Tightness : 5 ml / min
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October 2008 Jürgen Wüst
Ductile Oilpan
Stone - Chipping Resistance : 88J
Steel Ball : 4.5 lb / Ø 3.15 in Height of Fall : 13.8 ft
Energy : 88J (65 pound force-foot)
L =
13.8
ft
W =
88
Jo
ule
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October 2008 Jürgen Wüst
Ductile Oilpan
Alloy 380
Results (Alloy 380)
• Leak Tightness : 2 ml / min • Flange Hardness : 95 HB
• Elongation (Bottom) : 2 %
• Stone Chipping Resist.: 35 lb force-ft
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October 2008 Jürgen Wüst
Ductile Oilpan
Results (Alloy: Aural-5™)
• Leak Tightness : 2 ml / min • Flange Hardness : 88 HB
• Elongation (Bottom) : 10 %
• Stone Chipping Resist.: 96 lb force-ft
Aural-5™
As Cast
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October 2008 Jürgen Wüst
License Package
Per Diecasting Machine
- Vacuum Technology
- CCC-Monitoring
- Humidity Monitoring
- Metal Treatment Specifications
- Cold Chamber Metering Device
- Die Lube / Tip Lub Release Agent and Application
- Production Start-up Support
- Additional Support on Demand
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October 2008 Jürgen Wüst
License Package (cont.)
Diecasting Alloy AURAL™
- Guidelines (Melting, Casting)
- Chemical Composition (Specification)
- Melt Treatment
Heat Treatment AURALTHERM™
- Guidelines (Temperatures, Times)
- Air Quenching (Reduced Distortion)
Engineering Support
- DCM-Set-up, HT-Process, Melting,…
- Project Management (BDW – Licensee - OEM / Tier I)
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October 2008 Jürgen Wüst
Jack Branden
Vice President of Sales
Visi-Trak Worldwide
8400 Sweet Valley Drive, Suite 406 Valley View, OH 44125-4244
Office Phone: 800-252-8725 x32
Office FAX: 216-524-9594
www.Visi-Trak.com