Session 4 - Powertrain
Will J. Savage
Chief Executive, ALUMINIUM FEDERATION LTD, England
Session 4 consists of four presentations dealing with various aspects of powertrain. The session presentations run from 10:30 until 12:30 o'clock.
10:30-11:00 Potential of Aluminium Alloys for highly loaded Cylinder Heads
Dr.-Ing. Heinrich FuchsHead of Materials and Process Development, Honsel AG, Germany
Abstract
11:00-11:30 Spray formed Aluminium alloys for powertrain applications – materials, surface modification and joining technology
Peter KrugPEAK Werkstoff GmbH, Velbert, Germany
Abstract
Spray forming of aluminium alloys is one of the most favourable rapid solidification technologies which allows the combination of high solidification rates with a noticeably high production rate resulting in bulk material instead of powders or melt spun chips. Therefore a subsequent, complicated and contamination prone consolidation process to receive an extrudable billet can be omitted. Nevertheless, cooling rates achieved by spray forming is several times higher than in normal castings and only slightly smaller than in powder atomizing translate in sophisticated micro structures and outstanding properties of such alloys. High hot strength, high wear resistance, low thermal expansion and the highest ever measured fatigue limits are pronounced features of this group of materials, making them predestined for powertrain applications. Spray formed cylinder liners provided with a combination of high strength by precipitation and dispersoid hardening due to common as well as unusual alloying elements, high hardness and wear resistance by a high content of primary silicon crystals together with a high thermal conductivity due to the base metal aluminium, leads to an outstanding engine performance with very low friction losses.
Spray forming of aluminium alloys is one of the most favourable rapid solidification technologies which allows the combination of high solidification rates with a noticeably high production rate resulting in bulk material instead of powders or melt spun chips. Therefore a subsequent, complicated and contamination prone consolidation process to receive an extrudable billet can be omitted. Nevertheless, cooling rates achieved by spray forming is several times higher than in normal castings and only slightly smaller than in powder atomizing translate in sophisticated micro structures and outstanding properties of such alloys. High hot strength, high wear resistance, low thermal expansion and the highest ever measured fatigue limits are pronounced features of this group of materials, making them predestined for powertrain applications. Spray formed cylinder liners provided with a combination of high strength by precipitation and dispersoid hardening due to common as well as unusual alloying elements, high hardness and wear resistance by a high content of primary silicon crystals together with a high thermal conductivity due to the base metal aluminium, leads to an outstanding engine performance with very low friction losses.
11:30-12:00 Laser cleaning and de-coating applications of aluminium in powertrain production
Dipl.-Ing. Dipl-Kfm. Edwin BüchterClean-Lasersysteme GmbH, Herzogenrath, Germany
Abstract
Laser cleaning and de-coating of aluminium in power-train production
Highlights of the talk:
Laser cleaning a general introduction and overview
Opportunities and limits of flexible cleanLASER technology for aluminium applications
Latest status of laser cleaning technology and applications
Industrial application examples for laser cleaning of aluminium
Possibilities of in-line process control and laser based cleaning in place
Laser cleaning and de-coating of aluminium in power-train production
Highlights of the talk:
Laser cleaning a general introduction and overview
Opportunities and limits of flexible cleanLASER technology for aluminium applications
Latest status of laser cleaning technology and applications
Industrial application examples for laser cleaning of aluminium
Possibilities of in-line process control and laser based cleaning in place
12:00-12:30 Applicability and Employment of Aluminium Tailored Blanks in Automobile Industry
Dr.-Ing. Shahram Sheikhi
Schweißtechnische Lehr- und Versuchsanstalt SLV Duisburg, Duisburg, Germany
Abstract
Steel Tailored Welded Blanks (TWB) are extensively used by the automotive industry due to their positive effects on the total weight of bodywork parts and cost effectiveness because of the optimised usage of materials. In this way vehicle weight is decreased in order to reduce fuel consumption without compromising stiffness, durability and strength. Weight reduction is even more obvious (up to 55%) when replacing steel by aluminium. TWBs from aluminium alloys in with different thickness have been friction stir welded and are used in special cars now a days. The elaboration of a welding process window to produce sound welds with relevant parameters for industrial application was the aim of this investigation. The variation of the welding parameter specially the welding speed was a special feature of the work.
Sound welds have been produced with welding speeds ranging from 1 to 10 m/min. The applicability of the TWBs have been defined qualitatively via three point bending and metallographic examination. Further investigation on TWB samples have been carried out by means of tensile, punch and deep drawing testing. Since the uniaxial tensile test covers a very small portion of a stamping process only, the TWBs were formed into a complex part involving multi-forming modes. The shapes of the stamp and the die have been designed in such a way as to simulate real production conditions. The formed TWBs were analysed based on photogrammetric principles to evaluate the 3D-shape of the blanks surface, forming grades and the flow behaviour of the TWBs under multi-axial stresses. The analysis of the tested samples revealed plane strain as the critical deformation mode to be considered for further evaluations.
Steel Tailored Welded Blanks (TWB) are extensively used by the automotive industry due to their positive effects on the total weight of bodywork parts and cost effectiveness because of the optimised usage of materials. In this way vehicle weight is decreased in order to reduce fuel consumption without compromising stiffness, durability and strength. Weight reduction is even more obvious (up to 55%) when replacing steel by aluminium. TWBs from aluminium alloys in with different thickness have been friction stir welded and are used in special cars now a days. The elaboration of a welding process window to produce sound welds with relevant parameters for industrial application was the aim of this investigation. The variation of the welding parameter specially the welding speed was a special feature of the work.
Sound welds have been produced with welding speeds ranging from 1 to 10 m/min. The applicability of the TWBs have been defined qualitatively via three point bending and metallographic examination. Further investigation on TWB samples have been carried out by means of tensile, punch and deep drawing testing. Since the uniaxial tensile test covers a very small portion of a stamping process only, the TWBs were formed into a complex part involving multi-forming modes. The shapes of the stamp and the die have been designed in such a way as to simulate real production conditions. The formed TWBs were analysed based on photogrammetric principles to evaluate the 3D-shape of the blanks surface, forming grades and the flow behaviour of the TWBs under multi-axial stresses. The analysis of the tested samples revealed plane strain as the critical deformation mode to be considered for further evaluations.