Cost-effective aluminium die casting for automotive industry

Project Information

FC21S

Grant agreement ID: 733619

DOI

10.3030/733619

Project closed

EC signature date 27 July 2016

Start date 1 August 2016

End date 31 October 2018

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 1 877 978,75

EU contribution

€ 1 314 585,13

Coordinated by

FONDERIE CERVATI S.R.L
Italy

Periodic Reporting for period 5 - FC21S (Cost-effective aluminium die casting for automotive industry)

Reporting period: 2018-06-01 to 2018-10-31

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 2 - 6 ml (nebulized) each kg molten metal 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.
- Check and evaluate the microspray system at industrial scale.
- Optimize and design the new cooling mould system.
- Design and evaluate the new accumulation system for the new release agent.
- Last improvements and construction of the new release agent accumulation system. Compatibility assessment with the new the micro-spray and nebulisation system.
- Adaptation and testing of the new accumulation system is the real industrial environment.
- Construction and last improvements of the new cooling mould system.
- New lubrication dedicated head to apply the lubricant agent by positioning and not in movement process.
- First test with the nebulization head.
- Certification work.
- Validation of FC21S technology

Commercial and dissemination 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.
- Implement new commercial and dissemination actions with different stakeholders.
- Participation in METEF 2017 International Fair.
- Participation in EUROGUSS 2018 Intenational fair Nuremberg GERMANY.
- Participation in BIE (Brescia Industrial Exhibition).
- Meetings with new potencial custumers.

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 obtained have accomplished the expectations of the project.
As a result we will offer to our potential customers an innovative process and service with a look to the green future / environment.

Casting geometry

Die casting machine technology

Thermographic test