Thixoforming of Advanced Light Metals for Automotive Components

Objective

BE95-1244 Thixoforming of Advanced Light Metals for Automotive components
The pressure on car manufacturers to reduce weight is continuously increasing; this can effectively be achieved by replacing components traditionally made from iron and steel with new, possibly redesigned components made of light metals. Due to the higher material cost it is necessary to use more cost efficient manufacturing processes, e.g. near-net-shape thixoforming.
Three advanced material groups will be investigated: aluminium and magnesium alloys in addition to aluminium metal matrix composites (Al-MMCs).
The objectives of this proposal are therefore to:

- develop and produce advanced thixoformable alloys of Al, Al-MMCs and Mg, - study and model the thixoforming process,
- manufacture automotive components by near-net-shape thixoforming of all 3 alloy groups,
- determine the properties and performance of these real components, - assess the cost effectiveness of the process, and
- compare the overall properties and cost effectiveness of components made from the three light metal groups.

The following achievements are expected:

- near-net-shape thixoforming of minimum 3 light weight components with satisfactory properties and performance,
- weight reductions of 30-40% over components made from iron and steel - cost savings of min. 15-20% over light weight components made traditionally.

In addition to the research organisations/universities the Consortium consists of 3 material producers, 2 manufacturers and 2 very large industrial conglomerates as end-users. This combination of industrial partners will ensure a very fast exploitation of the results of this project.

Fields of science

• engineering and technology › mechanical engineering › manufacturing engineering
• engineering and technology › materials engineering › composites
• natural sciences › chemical sciences › inorganic chemistry › alkaline earth metals
• natural sciences › chemical sciences › inorganic chemistry › post-transition metals

Programme(s)

• FP4-BRITE/EURAM 3 - Specific research and technological development programme in the field of industrial and materials technologies, 1994-1998

Topic(s)

• 0201 - Materials engineering

Call for proposal

Data not available

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

RISOE NATIONAL LABORATORY

Address

Frederiksborgvej 399
Roskilde
Denmark

Links

Participants (10)

Aluminium Pechiney

France

Address

Centr'alp
38340 Voreppe

CENTRO RICERCHE FIAT S.C.P.A

Italy

Address

50,strada Torino, 50
10043 Orbassano

Links

EFU GESELLSCHAFT FUER UR-/UMFORMTECHNIK MBH

Germany

Address

22,jaegerhausstrasse 22
52152 Simmerrath

FOUNDATION FOR TECHNICAL AND INDUSTRIAL RESEARCH AT THE NORWEGIAN INSTITUTE OF TECHNOLOGY

Norway

Address

1,forskningsveien 1
0314 Oslo

Hydro Aluminium AS

Norway

Address

6601 Sunndalsora

INSTITUT NATIONAL POLYTECHNIQUE DE GRENOBLE

France

Address

101,rue De La Physique 101 Domaine Universitaire
38402 Saint-martin-d'heres

ITALIAN INSTITUTE FOR THE PHYSICS OF MATTER

Italy

Address

Via Ranieri 65, Istituto Di Scienze Fisiche
60131 Ancona

Norsk Hydro AS

Norway

Address

Heroya
3901 Porsgrunn

STAMPAL SPA

Italy

Address

Via Lombardia 6
10071 Borgaro Torinese

Volkswagen AG

Germany

Address

38436 Wolfsburg