Light-weighting Gravity Cast Parts in the Automotive Industry Jack - - PowerPoint PPT Presentation

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Light-weighting Gravity Cast Parts in the Automotive Industry Jack - - PowerPoint PPT Presentation

Light-weighting Gravity Cast Parts in the Automotive Industry Jack Strong Research Manager Page 1 Grainger & Worrall Ltd Grainger & Worrall Ltd TODAYS PRESENTATION Light-weighting Gravity Cast Parts in the Automotive Industry


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Grainger & Worrall Ltd Grainger & Worrall Ltd

Light-weighting Gravity Cast Parts in the Automotive Industry Jack Strong – Research Manager

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TODAY’S PRESENTATION

Light-weighting Gravity Cast Parts in the Automotive Industry

COMPANY INTRODUCTION SUPPORTING TECHNOLOGIES AUTOMOTIVE INDUSTRY CASTINGS NOVEL GRAIN REFINER DEVELOPMENT CONCLUSION

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Prototype business

  • Concept to Pre-Series
  • Focus on Low CO2 Vehicle solutions
  • Rapid technologies

Small Series business

  • High performance applications for Premium market
  • Supplied Cast – Machined – Part assembled
  • Gravity and Low Pressure (Cosworth process).

Motorsport business

  • F1 and high end Motorsport
  • Technology leading, innovative solutions.

GRAINGER & WORRALL CASTING FOUNDRY

Strategic Research Partner with BCAST

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TODAY’S PRESENTATION

Light-weighting Gravity Cast Parts in the Automotive Industry

COMPANY INTRODUCTION SUPPORTING TECHNOLOGIES AUTOMOTIVE INDUSTRY CASTINGS NOVEL GRAIN REFINER DEVELOPMENT CONCLUSION

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COMPUTATIONAL FLUID DYNAMICS SIMULATION (CFD) - MAGMASOFT

  • Cooling rate & integrity optimisation
  • Heterogeneous property mapping
  • Risk reduction and design optimisation
  • Residual stress mapping
  • Exportation to FEA (Magmalink)

Magma simulation supports product development and series casting process capability, with features including:

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DIGITAL MANUFACTURE – SAND PRINTING

Rapid production of complex low expansion sand cores for manufacture

  • f complex castings, e.g. Water jackets.

ExOne S-Print ExOne S-Max

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COMPUTER TOMOGRAPHY (CT) SCANNING

Utilising latest technology verification equipment for:

  • Rapid product development
  • Integrity inspection
  • Motorsport & Series parts validation
  • Reverse engineering

Other equipment includes;

  • 225kV GE XCUBE XL Realtime X-ray
  • GOM Optical Scanner
  • Laser ROMER arm
  • Multiple CMM Tactile

2x 450KV YXLON Machines

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TODAY’S PRESENTATION

Light-weighting Gravity Cast Parts in the Automotive Industry

COMPANY INTRODUCTION SUPPORTING TECHNOLOGIES AUTOMOTIVE INDUSTRY CASTINGS NOVEL GRAIN REFINER DEVELOPMENT CONCLUSION

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AUTOMOTIVE ENGINE DEMANDS & REQUIREMENTS

What the automotive industry wants from aluminium castings: Current state: Localised material temperatures exceeding 240°C

  • Efficiently remove waste heat from

combustion process

  • High material strength endurance.
  • 500,000,000 rev cycles over lifetime
  • Reduced wall thickness and weight.

Externally sourced video

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CYLINDER HEAD ALUMINIUM ALLOYS

A357 7 AlSi7Mg0.6 A354 4 AlSi9Cu3

A widely used alloy for automotive structural cast components due to its good strength, moderate ductility in the T6 condition and high thermal conductivity.

Density 2.67 g/cm3 Thermal Conductivity 151 W/m-K 0.2% proof stress 270 - 300 MPa UTS 310 - 330 MPa Elongation 2 - 7 %

β-Mg2Si Q-AlSiMgCu, β-Mg2Si Specified for higher strength applications, especially for elevated temperature performance at compromise of thermal conductivity.

Density 2.71 g/cm3 Thermal Conductivity 126 W/m-K 0.2% proof stress 290 - 310 MPa UTS 340 - 360 MPa Elongation 2 - 4 %

  • Note. Alloys grain refined by TiB2 (5:1)
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TODAY’S PRESENTATION

Light-weighting Gravity Cast Parts in the Automotive Industry

COMPANY INTRODUCTION SUPPORTING TECHNOLOGIES AUTOMOTIVE INDUSTRY CASTINGS NOVEL GRAIN REFINER DEVELOPMENT CONCLUSION

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NOVEL GRAIN REFINER - PLAN

  • Trial current level technology and increase maturity
  • Determine effectiveness of grain refiner
  • Identify opportunities for future use

Objectives

  • Identify suitable casting geometry
  • Trial the novel grain refiner on alloys containing different silicon levels
  • Evaluate the optimum potency of grain refiner by adjusting concentration
  • Use non-destructive analysis to evaluate results
  • Perform monotonic mechanical testing (Pending)
  • Identify benefit of grain refiner over existing methodology – Yield Reduction

Technology Readiness

Aim

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NOVEL GRAIN REFINER – EXPERIMENTAL

Benchmark NGR (2 types) against a control reference using current alloys: 2) A354

Control – No Grain Refiner - 3-off MA3 - Cast 3-off per condition; 0.1, 0.15, 0.2 wt% MA5 - Cast 3-off per condition; 0.1, 0.15, 0.2 wt%

1) A357

Control – 1)No Grain Refiner 2)TiB2 Refined 0.15 wt% MA3 - Cast 3-off per condition; 0.05, 0.1, 0.15 wt% MA5 - Cast 3-off per condition; 0.05, 0.1, 0.15 wt% 3) 3) Pre modified A357 – Fading trials; 0.1 wt% (4 hours)

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NOVEL GRAIN REFINER – EXPERIMENTAL t u v w x y z

Rating the level of shrinkage porosity: 1. None 2. Minor 3. Medium 4. Major 5. Severe

From CT scan images, a suitable comparative method was developed for quantifying the integrity of the casting.

Zone t u v w x y z Level

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NOVEL GRAIN REFINER – RESULT'S

Trial: Control – No Grain Refiner

Zone t u v w x y z Level 1 1 5 5 1 2 1

Alloy: A357 Concentration: 0.0wt% Gas Content: 0.4 Shrinkage rating: 2.29

u v w x t y z

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NOVEL GRAIN REFINER – RESULT'S

Trial: Control – Current state Alloy: A357 Concentration: 0.15 wt% TiB2 Gas Content: 0.4

Zone t u v w x y z Level 1 1 4 3 1 2 1

Shrinkage rating: 1.86

u v w x t y z

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NOVEL GRAIN REFINER – RESULT'S

Trial: NGR MA3

Zone t u v w x y z Level 1 1 4 3 1 2 1

Alloy: A357 NGR Concentration: 0.05 wt% Gas Content: 0.1 Shrinkage rating: 1.86

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 2 1 2 3 1 2 1

Trial: NGR MA3 Alloy: A357 NGR Concentration: 0.1 wt% Gas Content: 0.4 Shrinkage rating: 1.71

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 1 1 2 2 1 2 1

Trial: NGR MA3 Alloy: A357 NGR Concentration: 0.15 wt% Gas Content: 0.3 Shrinkage rating: 1.43

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NOVEL GRAIN REFINER – RESULT'S

A357 Reference vs. A357 0.15 wt% MA3 NGR

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NOVEL GRAIN REFINER – EVALUATION OF RESULTS

Trial NGR t u v w x y z 3 0.05 2 1 1 2 1 2 1 3.1 0.1 1 1 1 2 1 2 1 3.2 0.15 2 1 2 2 1 2 1 3.3 1 1 5 3 1 2 1 4.1 0.05 1 1 4 3 1 2 1 4.2 0.1 2 1 2 3 1 2 1 4.3 0.15 1 1 2 2 1 2 1

Trial: A357 (MA3 vs. MA5)

0.00 0.50 1.00 1.50 2.00 2.50 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16

Shrinkage rating Concentration [wt%]

MA5 MA3 TIB2

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 2 2 4 4 1 3 2

Trial: NGR MA5 Alloy: A354 NGR Concentration: 0.0 wt% Gas Content: 0.9 Shrinkage rating: 2.57

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 3 2 4 2 1 3 2

Trial: NGR MA5 Alloy: A354 NGR Concentration: 0.1 wt% Gas Content: 0.9 Shrinkage rating: 2.43

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 3 3 1 1 1 2 1

Trial: NGR MA5 Alloy: A354 NGR Concentration: 0.15 wt% Gas Content: 0.8 Shrinkage rating: 1.71

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NOVEL GRAIN REFINER – RESULT'S

Zone t u v w x y z Level 2 2 3 1 1 2 1

Trial: NGR MA5 Alloy: A354 NGR Concentration: 0.2 wt% Gas Content: 0.9 Shrinkage rating: 1.71

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NOVEL GRAIN REFINER – RESULT'S

A354 Reference vs. A354 0.15 wt% MA5 NGR

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NOVEL GRAIN REFINER – EVALUATION OF RESULTS

Trial NGR t u v w x y z 1 2 2 4 4 1 3 2 1.1 0.1 3 2 4 2 1 3 2 1.2 0.15 3 3 1 1 1 2 1 1.3 0.2 2 2 3 1 1 2 1 2.1 0.1 2 2 5 4 1 4 1 2.2 0.15 2 2 4 3 1 2 1 2.3 0.2 1 2 3 3 1 2 1

Trial: A354 (MA3 vs. MA5)

0.00 0.50 1.00 1.50 2.00 2.50 3.00

0.05 0.1 0.15 0.2 0.25

Shrinkage rating Concentration [wt%]

MA5 MA3

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NOVEL GRAIN REFINER – EVALUATION OF RESULTS

Work has also been supported by BCAST, providing etching inspection

Grain size is reduced from ~3 mm to ~0.3mm and is similar for all three addition rates.

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NOVEL GRAIN REFINER – RESULT'S

A357 – Fading trials; 0.1 wt% - 15 minutes vs 4 hours (after degas)

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NOVEL GRAIN REFINER – SUMMARY

  • Novel grain refiner (NGR) additions to A357 & A354 alloys refines the grain structure over TiB2.
  • Grain size is reduced, similar for all three addition rates.
  • NGR addition is observed to reduce macro porosity in the casting.

Future work

  • Evaluate fading and conduct further trials
  • Monotonic tensile testing
  • Further trial NGR on representative castings
  • Heat treatment trials (T6)
  • Look at effectiveness on recycled material
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Thank you for listening Any Questions