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Advanced semisolid forming of complex structural somponents

Objective



The object of this project is the production of safety
important structural component by aluminium semisolid
forming (Tixoforming). Semisolid forming is a relatively
new process of metal shaping in the semisolid state which
incorporates elements of both casting and forging.
This leads to technical and economic benefits:
high dimensional accuracy which enables the process to
be suitable for the production of near net shape parts
(important reduction of machining operations)
energy saving because the process requires only 50 60%
of the energy necessary for high pressure die casting
high mechanical properties (similar to the forging
ones)
better working conditions
longer die life
On such a base, the industrial goals of the project could
be summarised as follows:
1. overcoming the present limits of the thixoforming
process in order to produce net shape important
(weight>1kg) and complex structural components
2. definition of a methodology for die design and process
parameters optimisation which permits to reduce more than
30% the time necessary to obtain the first sound part.
The main expected deliverables of the project are the
following:
a methodology for component/die design and process
parameters optimisation based on experimental data and
process numerical simulation;
two different car component for structural, safety
application;
one aeronautical components for structural application;
one motorcycle component for structural application;
economical benefits evaluation.
The planned activities are structured for complementary
competencies (automotive, motorcycle, aeronautical, SME
industries) through quality methodologies in concurrent
engineering, design for process capabilities and
simultaneous cost analysis.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

CENTRO RICERCHE FIAT S.C.P.A
Address
50,Strada Torino, 50
10043 Orbassano
Italy

Participants (6)

ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS
France
Address
Avenue Claude Daunesse Cnrs Ura 1374
06565 Valbonne
EUROPEAN AERONAUTICS DEFENSE AND SPACE COMPANY EADS GIE
France
Address
Boulevard De Montmorency 37
75781 Paris
GIE Renault Recherche et Innovation
France
Address
860,Quai De Stalingrad 860
92109 Boulogne-billancourt
Nacional Motor SA
Spain
Address
19,Barcelona 19
8102 Martorelles
STAMPAL SPA
Italy
Address
Via Lombardia 6
10071 Borgaro Torinese
UNIVERSITAT POLITECNICA DE CATALUNYA
Spain
Address
S/n,campus Sud - Edif. Pe Avda. Diagonal, 647
08028 Barcelona