October 2008 Jürgen Wüst - Visi-Trak · Jürgen Wüst October 2008 Key Figures BDW technologies...

October 2008 Jürgen Wüst


Innovative

Vacuum

High Pressure Diecasting Technology

High-Q-Cast™


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


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®


Trapped gases -

(high magnification)

Typical Die Casting Defects

Shot from scanning electron microscope (SEM)


Areas indicating a

material separation

(Oxide)


Shot from scanning electron microscope (SEM)



Areas containing

shrinkage porosity

Magnification: 150 x


High-Q-Cast™

Standard

Vacuum

Diecasting

Standard

Diecasting

0 % 0.16 % 0.4 % 1 % 2.5 % Density Index DI

Gas Porosity inside Die Castings


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


Aural Alloys:

Special alloys have been developed to meet mechanical

properties of new applications


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


Process Analysis – Solidification

(Shrinkage Porosity)


Process Control – Die Temperature


Process Analysis – Die Fill (Gas Porosity)


Gate Calculation


Melt Treatment

Periodic Chemistry Check De-gassing


Sure-Trak2™ Shot Control System

Produce Precise and Repeatable Injection Control


A special shot sleeve lubricant application system has been developed to minimize

contamination of the cast part


High-Q-Cast™ Control Unit - Main Screen


High-Q-Cast™ Control Unit - Limit Set Point Screen

0.5 PSI


Components – Vacuum Line


Components – Coarse / Dust Filter


Components – Solenoid Valve


Components – Hydraulic Control Unit


Components – Vacuum Valve Activator


Components – Vacuum Die Valve


BDW has selected

some die release

chemistry that is

effective in minimizing

contamination of the

casting


Humidity Monitoring

Computer Controlled

Casting Software


Aural-2®

AlSi10MgMnFe


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


Property Potential of AURAL-2


Compression

test with

Aural-2 cast

structures

No cracks in the deformation zones!


Compression test with Aural-2 cast structures


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:


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)


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 %


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™“


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


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


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


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


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


Ductile Oilpan

Alloy 380

Results (Alloy 380)

• Leak Tightness : 2 ml / min • Flange Hardness : 95 HB


• Stone Chipping Resist.: 35 lb force-ft


Ductile Oilpan

Results (Alloy: Aural-5™)

• Leak Tightness : 2 ml / min • Flange Hardness : 88 HB


• Stone Chipping Resist.: 96 lb force-ft

Aural-5™

As Cast


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


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)


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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October 2008 Jürgen Wüst - Visi-Trak · Jürgen Wüst October 2008 Key Figures BDW technologies...

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