Community Research and Development Information Service - CORDIS


FC21S Report Summary

Project ID: 733619

Periodic Reporting for period 1 - FC21S (Cost-effective aluminium die casting for automotive industry)

Reporting period: 2016-08-01 to 2016-12-31

Summary of the context and overall objectives of the project

The reason of the project starts firstly with a look to the environmental protection. The standard process with traditional lubricant use a big quantity of liquid. Example: for a diecasting jet in terms of 3.5 Kg of aluminum are necessary 10 lt of water mixed oil of lubricant. A small % of this liquid stick on the steel as film to help the extraction but the biggest quantity of liquid become dirty waste. This is means that are necessary a big amount of tank and reflow disposal.
The new method of lubricant helps strongly the reduction of this disposal because for the same material will be necessary only 0,25 ml (nebulized) so it means that all liquid stick on the steel as film protection.
This new kind of lubricant is high performed with a “new” kind of alloy (Magsimal-59) where the mechanical properties are very high, comparing with standard alloys, and this could be used strongly in the automotive industries especially the chassis, helping the OEM (cars contractors) to use lighter material with thin thicknesses so cars lighter with less CO2 emission.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Technical work performed:
- Optimization of the chemical composition of the innovative mould release agent. Specifically to obtain better flow behaviour of the aluminium alloy, higher heat stability of the release agent, better protection against soldering, better corrosion resistant properties.
- Design and construction of the micro-spray and nebulisation system of the new release agent. Optimized spraying geometry has been defined, as well as air/liquid working pressures, tuning of release agent micro-dosing, liquid setting by step regulation.

Commercial work performed:
- Information activities at main customers involved in the automotive sector to make them aware of the potential innovation of the project and receive the first positive feedback

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The results until now are in line with the expectations of the project, test done and first results looks very good.
If everything will be confirmed positive, we will offer to our customer and therefore the consumers an innovative process and service with a look to the green future / environment.

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