Trends 1 2 3 GLOBAL CHARAC- MANUFACTURING TECHNOLOGY DEMANDS - - PowerPoint PPT Presentation

Aluminum Part and Component

Manufacturing Trends

GLOBAL DEMANDS CHARAC- TERIZATION CASTING FORGING EXTRUSION ROLL FORMING JOINING ADDITIVE MANUFACTURING

MANUFACTURING

TECHNOLOGY

2

1 2 3

GLOBAL TRENDS

TECHNOLOGY ROADMAP OF ALUMINUM

Current status Conventional lightweight

Moderate lightweight

Extreme lightweight

Cold forming Casting Extrusion Cold forming Hot forming Hydroforming Extrusion Additive manufacturing Joining Hot forming Extrusion Additive manufacturing

PROCESSES

Tool design Technology transfer Material waste High strength aluminum High precision parts Dissimilar materials Extremely high strength aluminum Surface quality High precision parts

CHALLENGES

Adapted from Thailand Automotive Institute, 2018

3

CASTING

5

CASTING

TECHNOLOGY TRENDS

• Casting of complex geometries

with integrated manifolds will need special core design

• Components are redesigned to

reduce assembly steps

• Weldability materials with

superior mechanical properties and microstructure

• Feasibility to join with other

components (dissimilar joining, welding, and bonding)

High pressure die casting (HPDC)

• High strength-to-weight ratio
• Alloying composition for stronger

materials

• In-process microstructure control
• Heat treatment
• Corrosion fatigues resistance
• Load bearing components
• Lack of endurance limit (some

alloys)

• Corrosive environment leads to early

fatigues failure

• Intelligent process based on data

analytic

Gravity casting

6

CASTING

MTEC RESEARCH ACTIVITY

Simulation software for gating and feeding system design Squeeze casting

Reduction in number and pressure

• f air bubbles for weldability and

heat treatability

7

CASTING

MTEC RESEARCH ACTIVITY

Database and SCADA for casting process control

8

CASTING

MTEC RESEARCH ACTIVITY

Inclusions in aluminum casting in Thailand

9

CASTING

MTEC RESEARCH ACTIVITY

Effect of atmospheric conditions on corrosion fatigue

FORGING

11

FORGING

TECHNOLOGY TRENDS

Load bearing components to replace Fe-based components

• Lack of experience in aluminum forging
• Unpredicted mechanical properties

because of uncertain microstructure

Challenges

Extrusion direction

12

FORGING

MTEC RESEARCH ACTIVITY

x y z Temperature heat treated: 450 ºC Soaking time: 20 min Cooling: Air

Cross section Cross section

Microstructure observation

• f extruded billet

Observation direction Parallel to direction Observation direction Perpendicular to direction

13

FORGING

MTEC RESEARCH ACTIVITY

20 mm 20 mm 20 mm 20 mm

Parallel to the ED Perpendicular to the ED

Extruded billet before heat treatment Extruded billet after heat treatment

14

FORGING

MTEC RESEARCH ACTIVITY

500 µm 200 µm 100 µm 50 µm 50 µm

Effect of process parameters on component properties and microstructure

EXTRUSION

16

EXTRUSION

MTEC RESEARCH ACTIVITY

Study of intermetallic phase transformation mechanism Observation of morphology change during heat treatment using synchrotron radiation

ROLL FORMING

18

ROLL FORMING

APPLICATIONS

Source: technologyinarchitecture.wordpress.com Adapted from Paralikas, I. N. , 2012

Aerospace industry

• Airframe stringers and longerons
• Interior components
• Stiffeners
• Jet engine components

Appliances industry

• Refrigerator panels
• Shelving, shell fronts
• Decorative trim, handles
• Back guard, rack-slide

Building/construction industry

• Channels and angles
• Metal roof decks
• Sliding panels
• Stiffeners and framing
• Sliding doors

Automotive industry

• Body-in-white structural parts
• Closure frames (doors, hinges)
• Seating track

Infrastructure

• Structural beams
• Joint beams
• Barriers
• Signing frames

Further applications

• Elevator cages
• Garage doors beams
• Tubes and bars
• Storage structures
• Etc.

19

Source: Chubu Engineering company

ROLL FORMING

CAPABILITY

Source: Paralikas, I. N. , 2012

Additional In-line Operation

Source: OMCO company Punching Sweeps Notching Embossing

VS

Steel Roll Forming Aluminum Extrusion

20

Source: Zou, T., et al., 2016

ROLL FORMING

MTEC PAST ACTIVITY: ROLL PASS TRY OUT AND APPROVAL

21

ROLL FORMING

BEYOND THE LIMITS

Tailor Coil Roll Forming

Varying Wall Thickness

Roll Forming 3D Roll Forming

Source: Data M company Source: TWB company Source: Welser company

JOINING

23

JOINING

APPLICATIONS

Aluminum rolling stock BIW structure FSW liquid-cooled plate Aluminum boat Aluminum bus

24

JOINING

ALUMINUM JOINING TECHNOLOGY

Source: Spinella, D., 2013

Fasteners & Adhesives

Adhesives Blind Fasteners Solid Rivets Bolts Self Pierce Rivets Clinching Flow Drill Screws Mechanical Interlock Electromagnetic Forming

Soldering

Dip Furnace Induction Infrared Iron Resistance Torch Wave

Brazing

Atmosphere Diffusion Dip Furnace Infrared Laser Resistance Torch

Solid-state

Cold Cold Spray / Welding Diffusion Explosion Friction Friction Stir Seam Friction Stir Spot Magnetic Pulse Ultrasonic

Resistance

Resistance Spot Weldbonding Resistance Seam Projection High Freq Resistance High Freq Induction Flash Upset, Pressure Gas Tungsten- Arc (TIG) Plasma Electron Beam Laser Beam Laser Hybrid GMAW

Room Temperature 450 °C 620°C and up

(Above melting point)

Gas Metal- Arc (MIG)

Fusion & Arc Welding

25

Welding

Source: Gullino, 2019

Brazing

Source: Center for Automotive Research, 2017

Cladding

Source: Kattire, 2015

JOINING

LASER JOINING TECHNOLOGY Roll-plating (Bonding)

Source: Fraunhofer IWS, 2014 Source: Kutsuna, 2010

Roll-welding

26

JOINING

COMBINATION OF DISSIMILAR MATERIALS IN CAR STRUCTURES

Ford truck F-150 (2015)

Aluminum body Steel frame

Audi A8

Audi Space Frame (ASF) Al + Mg + Steel + CFRP

2009 2018 Change 40.50% (17% PHS) Aluminum 92% 58%

• 34.00%

Other materials

• 1.50%

1.50% Steel 8% 32.50%

The right material

in the right place and in the right amount

27

JOINING

LASER WELDING AT MTEC Dissimilar joining

6kW fiber laser

• High precision and

consistency

• Complicated joining
• High strength with

high depth weld

• Less damages from

excess heat and contact

Advantages

Work in collaboration with Osaka university (JWRI)

• Joining of metallic foam and solid sheet

Preventing damages at metallic foam by excessive heat

• Direct joining of titanium and polyamide

by laser radiation

Enhanced joint strength by modifications of Ti

• xides layer

New joining techniques

Titanium Polyamide

28

JOINING

LASER WELDING AT MTEC

Dissimilar joining between aluminum alloys and high strength steel (780Y)

Steel Al

Shear tensile strength of the joint > 300 MPa Small spot (400 µm) fiber laser was applied in zigzag patterns to produce sufficient joining area for load bearing.

Joining of aluminum and polyamide6

ADDITIVE MANUFACTURING

30

ADDITIVE MANUFACTURING

MTEC TECHNOLOGY ROADMAP

Direct Energy Deposition Powder Bed Fusion

Source: lightmetalage.com

aluminum fuselage panel

Source: 3dprintingindustry.com

31

ADDITIVE MANUFACTURING

WIRE-BASED ADDITIVE MANUFACTURING (WAM) Wire materials

Low prices Widely available Minimized inventory space

Large-scale component printing

Robotic-controlled production No vacuum chamber required

Mechanical properties

with shorter lead time (10 kg/hr for steel)

Machine development

based on MTEC’s broad expertise in welding and robot system

Cost saving

Lower production costs for small batch production Example: Nickel-chromium steel component

Cost is reduced from 160,000 to 70,000 THB

Advanced component design

Multi-material components for tailored properties

Why WAM?

32

ADDITIVE MANUFACTURING

WIRE-BASED ADDITIVE MANUFACTURING (WAM) KEY FEATURES Fast printing speed Cost saving

Aluminum alloy wire choices include 1100, 2024, 2318, 2319, 3000 series, 4043, 4047, 5087, 5183, 5356, 5554, and 5556.

Source: ramlab.com

33

ADDITIVE MANUFACTURING

WIRE-BASED ADDITIVE MANUFACTURING (WAM) ON-DEMAND INDUSTRIAL REPLACEMENT

Business opportunities: Industrial parts

• Real-time process monitoring
• Adaptive printing strategies
• CAE-based design
• Possibilities for AI integrated algorithms
• Material characterization
• Optional post-processing for enhanced

properties

Energy industry Oceanic/

• ffshore

industry

Source: mx3d.com Source: 3dprintingindustry.com

34

Material developer

New material for AM Application-based alloying for AM

Technology consultant

Application-based process selection

Material expert

AM part reliability testing Post-processing guidelines Surface treatment for AM

Technology developer

New wire-AM system Printing strategy optimizer Thermal stress prediction

Solution provider

AM cost/benefit analysis Component design

ADDITIVE MANUFACTURING

MTEC EXPERTISE

MATERIAL CHARACTERIZATION

36

Charac- terization

• From sub-atomic to

macro structure

• Microscopy or

Spectroscopy

• Mechanical properties
• Chemical properties
• Electrical

properties

• Thermal

properties

• Casting
• Powder

Processing

• Bulk Deformation

MATERIAL CHARACTERIZATION

MATERIALS PARADIGM

37

MATERIAL CHARACTERIZATION

X-RAY COMPUTED TOMOGRAPHY (X-RAY CT)

Source: Xu et al., 2019

38

Source: Villarraga-Gómez et al., 2018

Inconel and Al powder for additive manufacturing

Source: Jeon et al., 2010

Al foam and internal pore structure

MATERIAL CHARACTERIZATION

X-RAY MICRO CT APPLICATIONS Image-based finite element analysis Internal features and inclusions

39

• Surfaces
• Reverse engineering
• Metrology: shape, size, thickness and dimensions
• Nominal/actual shape-size comparison

1mm 1mm As-printed Polished

Source: Kerckhofs et al., 2012

Additively manufactured Ti64 Part to CAD comparison of flexure

Source: Villarraga et al., 2015

MATERIAL CHARACTERIZATION

X-RAY MICRO CT APPLICATIONS

40

FREE seminar

3D Micro CT

for Non-destructive Material Characterization

(Conducted in English)

Location: MR214 Room, BITEC Date: 22 November 2019 Time: 9:30 – 12:00

Please RSVP at