presentation of an innovation RoBoC = Roll Bond Core - PowerPoint PPT Presentation

presentation of an innovation RoBoC = Roll Bond Core www.aionacast.com info@aionacast.com

Introduction of company AionaCast INTRODUCTION AionaCast Consulting GmbH Vaihingen an is located in the South of der Enz Germany. ST A TUS QUO Established in 2010 INNOV A TION AionaCast is involved in all aspects of the aluminum castings business: IMPLEMENT A TION The company does not have an own production facility, we did set ADV ANT AGES up collaborations with partners who Marketing Sales Development own adequate production capacities in the required fields. Trouble- OFFER Consulting Engineering shooting 22.01.2020 2 I

Share of new vehicle sold, percent EV breakthrough scenario China EU INTRODUCTION ST A TUS QUO INNOV A TION RoW US IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 3 I Quelle Bild: McKinsey & Company, Reboost Report, A comprehensive view on the changing powertrain component market and how suppliers can succeed

E - engines INTRODUCTION ST A TUS QUO INNOV A TION All new traction e-engine housings for electric driven IMPLEMENT A TION passenger cars and trucks are liquid cooled. ADV ANT AGES OFFER 22.01.2020 4 I Quelle Bild: https://www.springerprofessional.de/automobil---motoren/elektromotor/bosch-elektromotor-32-kilogramm-leicht-und- mit-geringem-volumen/6585368

Creating innovation… It should The problem we would like to solve is: INTRODUCTION present the How to offer a production process following for the cooling channels, which is ST A TUS QUO features: at the same time easier, cheaper and of a higher quality? No assembly process, just INNOV A TION one casting for the housing, potentially including other features such as a gear Suitable for high volume IMPLEMENT A TION box, etc. production -cheap- ADV ANT AGES Flexible No risk of leakage Scalable in layout of the length and cooling Weight Uniform diameter Low pressure OFFER channels reduction cooling drop 22.01.2020 5 I

Our idea, which is already patent pending INTRODUCTION PCT/EP2017/000304 What makes this innovation really stand out, is the perfect combination of a ST A TUS QUO standard casting process with the common roll- INNOV A TION bonding production method used for the light metal sheet We insert a light metal sheet package! IMPLEMENT A TION package, which already includes all cooling channels and connectors, in a die for ADV ANT AGES Hence the innovation is named gravity or low pressure die casting and we recast it with RoBoC aluminum. OFFER ( Ro ll Bo nd C ore) 22.01.2020 6 I

Realization 1. INTRODUCTION Manufacturing of a Roll bond, ST A TUS QUO ready to be inserted INNOV A TION Cutting IMPLEMENT A TION Brushing Screen Quenching Printing Oven Oven Rolling ADV ANT AGES Pressurized OFFER Air Forming Inflation 22.01.2020 7 I Quelle Bild: Muhr und Bender KG (MUBEA)

Realization 1. 2. 3. INTRODUCTION Manufacturing of a Roll bond, ST A TUS QUO ready to be inserted Inserting the light metal Closing of sheet package in the die the die INNOV A TION 4. 5. 6. IMPLEMENT A TION Filling the die with molten metal and cooling of the RoBoC from inside during ADV ANT AGES filling Taking out the → Avoiding fuse of the Solidification casting of the die RoBoC OFFER 22.01.2020 8 I

Design options INTRODUCTION Single Side Inflated Two Side Inflated with the help of different aluminum material grades ST A TUS QUO or INNOV A TION IMPLEMENT A TION ADV ANT AGES The thickness of each sheet is Geometric tolerances are similar to Stable up to a burst approximately 0,5 to the standard sand core process pressure of 60 bar OFFER 2,5 mm 22.01.2020 9 I

Implementation INTRODUCTION ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES Example of a design (Helix) for the inserted metal sheet OFFER 22.01.2020 10 I

Implementation INTRODUCTION ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES Example of a design for the inserted metal sheet, temperature spreading OFFER 22.01.2020 11 I

Implementation INTRODUCTION ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES Example of a design for the inserted metal sheet, cross-section OFFER 22.01.2020 12 I

Implementation (proof of concept) INTRODUCTION ST A TUS QUO INNOV A TION Cut e-engine housing IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 13 I

Implementation (proof of concept) INTRODUCTION ST A TUS QUO INNOV A TION E-engine housing with connectors IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 14 I

Implementation (proof of concept) INTRODUCTION ST A TUS QUO INNOV A TION E-engine housing with connectors IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 15 I

Result The result is a smooth embedded metal sheet with the shapes INTRODUCTION for the cooling channels integrated in the casting. ST A TUS QUO INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 16 I

Implementation INTRODUCTION ST A TUS QUO Generation 1 INNOV A TION IMPLEMENT A TION ADV ANT AGES OFFER 22.01.2020 17 I

Cost advantages INTRODUCTION Elimination of non value-added operations One piece of casting, no machining ST A TUS QUO highly additional machinery or necessity to and complex assembly process remove the associated sand core necessary - means sand core closing of the production INNOV A TION core prints simplification of the process Much less CNC IMPLEMENT A TION Elimination of the machining flow rate and leak pressure test after ADV ANT AGES Shorter cycle times for casting / assembly the casting process in reason of cooling from Less OFFER inside during casting casting scrap 22.01.2020 18 I

Technical advantages Cooling of the INTRODUCTION High stability of the housing, channels during compared to a 2 shell design and pouring and therefore less weight and less solidification of the ST A TUS QUO required installation space molten metal, means weight better mechanical reduction of properties of the up to 1 kg INNOV A TION Helix-Cooling design could reduce casting the size of the total engine in reason of higher cooling efficiency IMPLEMENT A TION Split of the requirement for mechanical stability and parallel no risk for leakage and tightness channels are ADV ANT AGES residual dirt possible The process is also suitable for battery housings, power unit housings, OFFER junction boxes and other similar applications 22.01.2020 19 I

Offer We can offer business cases … INTRODUCTION delivery of ready for assembly e-engine a. ST A TUS QUO housings (with partner) b. INNOV A TION licenses c. IMPLEMENT A TION rights of the patent pending d. ADV ANT AGES shares in a company AionaCast Engineering … get in touch with us! OFFER 1/22/2020 20 I

Thank you for your attention! www.aionacast.com info@aionacast.com