Ultra High Strength Aluminium Alloys for the Automotive Large-Scale Production
Solutions for structural vehicle components from ultra high-strength aluminium alloys, which can provide an alternative for ultra high-strength (hot formed) boron steels, will be worked out in this project. Thereby the optimisation of the process chain “from sheet to component” is in the center with the target of a production suitable for large-scale. Further project focuses will be new / adapted joining concepts as well as new simulation tools for the process (forming simulation) and component simulation (crash).
Prediction of Final Properties
Detailed knowledge of the heat treatment process of aluminum castings has the potential to lower the energy consumption during heat treatment, take full advantage of the material’s potential and increase the competitiveness of the casting industry in general.
Design and Process Development of hollow structural HPDC Components (high Pressure Die Cast)
- Substitution of welded steel sheet components e.g. torque box
- Adopt casting to Joining Technology/ Develop appropriate joining technology
- Casting process development (HPDC) of hollow structural component using lost cores
- Design of weight reduced Al-component (casting)
Tailor rolling of High Strength Aluminium Alloys
The usage of Aluminum alloys has significantly increased in recent years leading to a substantial weight reduction. This weight reduction trend has to be maintained to additional light weighting technologies. Tailor rolled Blanks (TRB) offer an interesting solution through an adequate thickness distribution through the blank allowing for an optimized usage of the weight where it is requested. This technology is however restricted right now to steels. The industrial feasibility of TRB with high strength Aluminum alloys still needs to be demonstrated. In particular the solution heat treatment phase which is necessary in order to guarantee final properties needs to be demonstrated.
Aluminum Casting for High Volume Production of Structural Nodes in BIW
Decreasing the body in white’s (BIW) weight is considered as one of the solutions, which might have a great impact on the emissions’ reduction potential.
This weight reduction can be achieved by the integration of lightweight materials, such as Aluminum, in the vehicle body structures, in the form of castings.
Ultrasonic Particle Detector
Main objective of this project is to develop an ultrasonic detector for non-metallic inclusions in aluminum melts, which is able to verify melt quality and is able to operate under industrial conditions. Research focus is to develop a measurement system that ensures a high reproducibility and continuity regarding the measurement results. Furthermore, the measurement system is supposed to operate without expert knowledge.
UniCorn - Understanding the Intergranular Corrosion of 6000 Aluminium Alloys
The present project will undertake a methodical investigation on the mechanism of intergranular corrosion in 6000 alloys. The influence of the Mg/Si ratio, the copper content, and the heat treatment on phase precipitation and its effect on intergranular corrosion will be analyzed.
Cast Part Feasibility Assessment Method
In-service performance of cast parts not only depends on part design, but also on manufacturing effects like part orientation in mold, gating & feeder system (size, location) and process parameters (filling rates, melt & die temperatures). Casting process restrictions and requirements are of equal importance as attribute requirements (strength, durability, NVH, crash).
Conventional component optimization relies on expert skills and expert guided analysis loops. MDO tools as well as design engineers require fully automated tools & expert systems to evaluate the feasibility and quality of cast parts upfront, quantitatively and efficiently.
The objective is to develop an automatic tool set to run casting simulations, to quantify existing casting process know-how, to make it available for automatic evaluation schemes and to provide validation example parts. more...