october 2008 jürgen wüst - visi-trak · jürgen wüst october 2008 key figures bdw technologies...
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October 2008 Jürgen Wüst
October 2008 Jürgen Wüst
Innovative
Vacuum
High Pressure Diecasting Technology
High-Q-Cast™
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
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®
October 2008 Jürgen Wüst
Trapped gases -
(high magnification)
Typical Die Casting Defects
Shot from scanning electron microscope (SEM)
October 2008 Jürgen Wüst
Areas indicating a
material separation
(Oxide)
Typical Die Casting Defects
Shot from scanning electron microscope (SEM)
October 2008 Jürgen Wüst
Typical Die Casting Defects
Areas containing
shrinkage porosity
Magnification: 150 x
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
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
October 2008 Jürgen Wüst
Aural Alloys:
Special alloys have been developed to meet mechanical
properties of new applications
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
October 2008 Jürgen Wüst
Process Analysis – Solidification
(Shrinkage Porosity)
October 2008 Jürgen Wüst
Process Control – Die Temperature
October 2008 Jürgen Wüst
Process Analysis – Die Fill (Gas Porosity)
October 2008 Jürgen Wüst
Gate Calculation
October 2008 Jürgen Wüst
Melt Treatment
Periodic Chemistry Check De-gassing
October 2008 Jürgen Wüst
Sure-Trak2™ Shot Control System
Produce Precise and Repeatable Injection Control
October 2008 Jürgen Wüst
A special shot sleeve lubricant application system has been developed to minimize
contamination of the cast part
October 2008 Jürgen Wüst
High-Q-Cast™ Control Unit - Main Screen
October 2008 Jürgen Wüst
High-Q-Cast™ Control Unit - Limit Set Point Screen
0.5 PSI
October 2008 Jürgen Wüst
Components – Vacuum Line
October 2008 Jürgen Wüst
Components – Coarse / Dust Filter
October 2008 Jürgen Wüst
Components – Solenoid Valve
October 2008 Jürgen Wüst
Components – Hydraulic Control Unit
October 2008 Jürgen Wüst
Components – Vacuum Valve Activator
October 2008 Jürgen Wüst
Components – Vacuum Die Valve
October 2008 Jürgen Wüst
BDW has selected
some die release
chemistry that is
effective in minimizing
contamination of the
casting
October 2008 Jürgen Wüst
Humidity Monitoring
Computer Controlled
Casting Software
October 2008 Jürgen Wüst
Aural-2®
AlSi10MgMnFe
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
October 2008 Jürgen Wüst
Property Potential of AURAL-2
October 2008 Jürgen Wüst
Compression
test with
Aural-2 cast
structures
No cracks in the deformation zones!
October 2008 Jürgen Wüst
Compression test with Aural-2 cast structures
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:
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)
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 %
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™“
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
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
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
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
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
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
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
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
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)
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
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