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Vacuum-assisted high pressure die castings with reduced porosity at low cost

Objective

The necessity of preserving resources and to reduce environmental pollution makes light weight concepts and recycling highly interesting for the transportation market, being light weight essential for newly developed electric and hybrid vehicles.

At the present, the use of aluminium high pressure die castings for structural applications in the automotive industry is limited due the presence of porosity inherent to the fabrication process. High vacuum processes can reduce porosity significantly, but both the capital investment and the process costs are very high.

On the other hand, the use of cheaper adaptable vacuum systems it is still not very popular in SME foundries, despite of significant technological improvements during the last years; this is mainly because of the complexity of this process, the need for improved process stability and deeper metallurgical knowledge of the alloys used in these new applications.

The aim of the SOUNDCAST project is to provide the SME die caster with an innovative and environmentally friendly technology to produce sound and weldable high performance castings by a low cost vacuum assisted high pressure die casting (VPDC) process.

During the project the link between the most important parameters that enhance porosity will be established, and a versatile technology package which optimizes the whole fabrication process will be developed including:
- Numerical simulation of die filling and solidification
- Special die design
- Use of a “state of the art vacuum” valve
- HPDC process parameter optimization
- Optimized die and shot sleeve lubrication for welding applications
- Development of quality control software
- Development of a new recycled alloy(s) with high mechanical properties
- Melt and heat treatment optimization for the new recycled alloy(s)
- Development of a new laser welding process at reduced pressure
The developed know-how and technologies will be demonstrated and validated in SME foundries.

Call for proposal

FP7-SME-2012
See other projects for this call

Coordinator

CASA MARISTAS AZTERLAN
Address
Aliendalde Auzunea 6
48200 Durango
Spain
Activity type
Research Organisations
EU contribution
€ 18 983,72
Administrative Contact
Ana Fernandez (Mrs.)

Participants (9)

FUNDACIO PRIVADA ASCAMM

Participation ended

Spain
Address
Avenida Universitat Autonoma , Parc Tecnologic Del Valles 23
08290 Cerdanyola Del Valles
Activity type
Research Organisations
Administrative Contact
Fernando Porcel (Mr.)
V.D.S. VACUUM DIECASTING SERVICE SA
Switzerland
EU contribution
€ 358 919,50
Address
Zone Industrielle De La Foge E
1816 Chailly-montreux
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Christophe Bagnoud (Dr.)
CHEM-TREND (DEUTSCHLAND) GMBH
Germany
EU contribution
€ 8 627
Address
Ganghoferstrasse 47
82216 Maisach Gernlinden
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Norbert Ehlers (Mr.)
DISTRIBUTION DE L ALUMINIUM COULE ELABORE SAS

Participation ended

France
EU contribution
€ 262 259,60
Address
Zone Industrielle
46110 Vayrac
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Matthieu Hede (Mr.)
ALUMINIO INYECTADO ALIASA SL

Participation ended

Spain
EU contribution
€ 178 527,90
Address
Carretera Bilbao Vitoria Km 22
48140 Igorre
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Mikel Egiazu (Mr.)
FUNDACIO EURECAT
Spain
Address
Avenida Universitat Autonoma 23
08290 Cerdanyola Del Valles (Barcelona)
Activity type
Research Organisations
Administrative Contact
Fernando Porcel (Mr.)
TECHNISCHE UNIVERSITAET BRAUNSCHWEIG
Germany
Address
Universitaetsplatz 2
38106 Braunschweig
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Helge Pries (Dr.)
RUFFINI SA
Spain
EU contribution
€ 141 504,45
Address
Avda Compositor Bizet 2
08191 Rubi
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Jose Maria Ripol (Mr.)
SCHMALE & SCHULTE GMBH
Germany
EU contribution
€ 146 177,78
Address
An Der Bellmerei 1
58566 Ludenscheid
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Steffen Greis (Mr.)