Aluminum Part and Component Manufacturing Trends
1 2 3 GLOBAL CHARAC- MANUFACTURING TECHNOLOGY DEMANDS TERIZATION CASTING FORGING EXTRUSION ROLL FORMING JOINING ADDITIVE MANUFACTURING 2
GLOBAL TRENDS TECHNOLOGY ROADMAP OF ALUMINUM Adapted from Thailand Automotive Institute, 2018 Extreme Moderate Current Conventional lightweight status lightweight lightweight Hot forming Joining Extrusion Cold forming Hydroforming Hot forming PROCESSES Cold forming Casting Extrusion Extrusion Additive manufacturing Additive manufacturing Dissimilar materials Technology transfer High strength aluminum Extremely high strength aluminum CHALLENGES Tool design Material waste High precision parts Surface quality High precision parts 3
CASTING
CASTING TECHNOLOGY TRENDS High pressure die Gravity casting casting (HPDC) • High strength-to-weight ratio • Casting of complex geometries • Alloying composition for stronger with integrated manifolds will materials need special core design • In-process microstructure control • Components are redesigned to • Heat treatment • Corrosion fatigues resistance reduce assembly steps • Load bearing components • Weldability materials with • Lack of endurance limit (some superior mechanical properties alloys) and microstructure • Corrosive environment leads to early • Feasibility to join with other fatigues failure components (dissimilar joining, • Intelligent process based on data welding, and bonding) analytic 5
CASTING MTEC RESEARCH ACTIVITY Simulation software for gating and feeding system design Squeeze casting Reduction in number and pressure of air bubbles for weldability and heat treatability 6
CASTING MTEC RESEARCH ACTIVITY Database and SCADA for casting process control 7
CASTING MTEC RESEARCH ACTIVITY Inclusions in aluminum casting in Thailand 8
CASTING MTEC RESEARCH ACTIVITY Effect of atmospheric conditions on corrosion fatigue 9
FORGING
FORGING TECHNOLOGY TRENDS Load bearing components to replace Fe-based components Challenges • Lack of experience in aluminum forging • Unpredicted mechanical properties because of uncertain microstructure 11
FORGING MTEC RESEARCH ACTIVITY Microstructure observation of extruded billet Cross section Parallel to direction Temperature heat treated: 450 ºC Soaking time: 20 min Cooling: Air Extrusion Observation direction direction y x z Perpendicular to direction Observation direction Cross section 12
FORGING MTEC RESEARCH ACTIVITY Parallel to the ED Perpendicular to the ED Extruded billet before heat treatment 20 mm 20 mm Extruded billet after heat treatment 20 mm 20 mm 13
FORGING MTEC RESEARCH ACTIVITY Effect of process parameters on component properties and microstructure 500 µ m 200 µ m 50 µ m 100 µ m 50 µ m 14
EXTRUSION
EXTRUSION MTEC RESEARCH ACTIVITY Observation of morphology change during heat treatment Study of intermetallic phase using synchrotron radiation transformation mechanism 16
ROLL FORMING
ROLL FORMING APPLICATIONS Automotive industry Aerospace industry • Airframe stringers and longerons • Body-in-white structural parts • Interior components • Closure frames (doors, hinges) • Seating track • Stiffeners • Jet engine components Appliances industry Infrastructure • Refrigerator panels • Structural beams • Shelving, shell fronts • Joint beams • Decorative trim, handles • Barriers • Back guard, rack-slide • Signing frames Building/construction industry Further applications • Channels and angles • Elevator cages • Metal roof decks • Garage doors beams • Sliding panels • Tubes and bars • Stiffeners and framing • Storage structures • Sliding doors • Etc. Source: technologyinarchitecture.wordpress.com Adapted from Paralikas, I. N. , 2012 18
ROLL FORMING CAPABILITY Source: Chubu Engineering company Steel Aluminum VS Roll Forming Extrusion Source: Paralikas, I. N. , 2012 Additional In-line Operation Punching Sweeps Notching Embossing Source: OMCO company 19
ROLL FORMING MTEC PAST ACTIVITY: ROLL PASS TRY OUT AND APPROVAL 20 Source: Zou, T., et al., 2016
ROLL FORMING BEYOND THE LIMITS Varying Wall Thickness Tailor Coil Roll Forming 3D Roll Forming Roll Forming Source: Data M company Source: TWB company Source: Welser company 21
JOINING
JOINING APPLICATIONS BIW structure Aluminum bus Aluminum boat Aluminum rolling stock FSW liquid-cooled plate 23
JOINING ALUMINUM JOINING TECHNOLOGY Room 620 ° C and up 450 ° C Temperature (Above melting point) Fasteners Fusion & Soldering Brazing Solid-state Resistance & Adhesives Arc Welding Adhesives Cold Dip Atmosphere Resistance Spot Gas Metal- Arc (MIG) Cold Spray / Blind Fasteners Furnace Diffusion Weldbonding Welding Gas Tungsten- Solid Rivets Diffusion Arc (TIG) Induction Dip Resistance Seam Bolts Explosion Plasma Infrared Furnace Projection Self Pierce Rivets Friction High Freq Iron Infrared Electron Beam Resistance Friction Stir Clinching Seam High Freq Resistance Laser Induction Flow Drill Screws Friction Stir Spot Laser Beam Mechanical Torch Resistance Flash Magnetic Pulse Interlock Laser Hybrid Electromagnetic Wave Torch Upset, Pressure Ultrasonic GMAW Forming 24 Source: Spinella, D., 2013
JOINING LASER JOINING TECHNOLOGY Welding Cladding Brazing Source: Gullino, 2019 Source: Center for Automotive Research, 2017 Source: Kattire, 2015 Roll-welding Roll-plating (Bonding) Source: Kutsuna, 2010 Source: Fraunhofer IWS, 2014 25
JOINING COMBINATION OF DISSIMILAR MATERIALS IN CAR STRUCTURES The right material in the right place and in the right amount Ford truck F-150 (2015) Aluminum body Steel frame Audi A8 Audi Space Frame (ASF) Al + Mg + Steel + CFRP 2009 2018 Change Steel 8% 40.50% 32.50% (17% PHS) Aluminum 92% 58% -34.00% Other - 1.50% 1.50% materials 26
JOINING LASER WELDING AT MTEC New joining techniques Advantages • High precision and • Joining of metallic foam and solid sheet consistency • Complicated joining • High strength with high depth weld • Less damages from excess heat and contact Preventing damages at metallic foam by excessive heat • Direct joining of titanium and polyamide by laser radiation Polyamide Titanium Enhanced joint strength by modifications of Ti Dissimilar joining oxides layer 6kW fiber laser Work in collaboration with Osaka university (JWRI) 27
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 Joining of aluminum and polyamide6 Small spot (400 µ m) fiber laser was applied in zigzag patterns to produce sufficient joining area for load bearing. 28
ADDITIVE MANUFACTURING
ADDITIVE MANUFACTURING MTEC TECHNOLOGY ROADMAP Direct Energy Deposition Powder Bed Fusion aluminum fuselage panel Source: 3dprintingindustry.com 30 Source: lightmetalage.com
ADDITIVE MANUFACTURING WIRE-BASED ADDITIVE MANUFACTURING (WAM) Large-scale component printing Cost saving Robotic-controlled production Lower production costs for small batch production No vacuum chamber required Example: Nickel-chromium steel component Why Cost is reduced from 160 ,000 to 70 , 000 THB Mechanical properties with shorter lead time (10 kg/hr Wire materials WAM? for steel) Low prices Widely available Machine development Minimized inventory space based on MTEC’s broad expertise Advanced component design in welding and robot system Multi-material components for tailored properties 31
ADDITIVE MANUFACTURING WIRE-BASED ADDITIVE MANUFACTURING (WAM ) KEY FEATURES Fast printing speed Cost saving Source: ramlab.com Aluminum alloy wire choices include 1100, 2024, 2318, 2319, 3000 series, 4043, 4047, 5087, 5183, 5356, 5554, and 5556. 32
ADDITIVE MANUFACTURING WIRE-BASED ADDITIVE MANUFACTURING (WAM ) ON-DEMAND INDUSTRIAL REPLACEMENT Source: mx3d.com 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 Oceanic/ offshore properties industry Energy industry Source: 3dprintingindustry.com 33
ADDITIVE MANUFACTURING MTEC EXPERTISE Solution provider AM cost/benefit analysis Component design Material expert Technology developer New wire-AM system AM part reliability testing Printing strategy optimizer Post-processing guidelines Surface treatment for AM Thermal stress prediction Technology consultant Material developer New material for AM Application-based Application-based alloying for AM process selection 34
MATERIAL CHARACTERIZATION
MATERIAL CHARACTERIZATION MATERIALS PARADIGM • From sub-atomic to • Mechanical properties macro structure • Chemical properties • Microscopy or • Electrical Spectroscopy properties • Thermal Charac - properties terization • Casting • Powder Processing • Bulk Deformation 36
MATERIAL CHARACTERIZATION X-RAY COMPUTED TOMOGRAPHY (X-RAY CT) Source: Xu et al., 2019 37
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