Exploitable results LKR Numerical CALPHAD Approach of Magnesium Alloys in the Aluminium-Zink-Manganese Region in the semi-solid region.(Prediction of Semi-Solid Temperature at a given composition) When casting alloys in the semi-solid state with the New Rheocasting Process, usually a 50% solid fraction is located. Up to now, for each alloy a special temperature is given, at which the casting will take place, for instance about 580°C for A356, one of the most common alloys. For semi-solid casting it is very important that in the semi-solid range the alloy has a high tolerance in temperature so that for 1°C change the solid fraction changes just minimally, which is 1% for A356. However, with other alloys, the temperature tolerance is much lower, so that 1°C change produces up to 4% change in solid fraction. The New Rheocasting Process has a stability of about ±1,5 to 2°C, which would mean a change of maximal ±8% of solid. This would still work. However every alloy has a tolerance in its composition. But a change in element content changes also the solidification curve, as can be seen in the technical report. So it would mean that one casts at 65% solid while thinking of 50% solid fraction and therefore produces bad parts. An awareness of high tolerance intervals in alloys that change semi-solid temperature of given alloy with different composition makes one think of how to know the exact semi-solid temperature in order to ensure secure high-quality casting. There are expensive programs like Thermocalc or JMatPro that can do that, but this takes time and costs money. LKR now made numerical approximations based on the calphad approach for the alloys 2024, 356, 357 (Aluminium) and AM50 to AZ91 (Magnesium with Al, Mn, Zn Elements) in order to provide the cast shop with the necessary information. Innovative aluminium alloys Recent R & D has shown that low Cu additions in the order of 0.30 to 0.50 to the basic AlSi7Mg0.6 combined to specific aging treatments lead to a potentially attractive compromise, while the resistance to stress corrosion cracking is still good (the alloy passed the ASTM test of 60 days under a stress equal to 75% of the YS). A further reduction in silicon to 5% appears to improve the elongation without reducing the strength. This small addition of Cu does not materially alter the Fs (T) curves around 50% solid, but leads to lower final eutectics. Tendency to micro shrinkage will have to be checked. The reduction of Si from 7 to 5 leads to a solid fraction of » 65% if one chooses to operate the NRC process just above the eutectic at 575°C. Another possibility would be to work at 590°C to retain 50% liquid, which would ultimately solidify as a mixture of fine µAl dendrites + µAl-Si eutectic. AlSi7CuMg, code named ¿87S1¿, and AlSi5CuMg, ¿85S1¿, should be tested on the automobile components of this program. The alloy 25Z used for the experiments has been obtained from the alloy Al Cu5MgTi received from Pechiney (500 kg about), by adding pure Zn, Mn 75% mother alloy and Cu 33% mother alloy. The initial composition of the ingots received, the final molten bath composition and the theorical composition indicated by Pechiney are indicated in table 4: 2 elements are out of tolerance, the Si due to the small quantity of 87S alloy remained into the holding furnace and the iron, already present into the ingots. Innovative Magnesium alloys Current Mg allorys are investigated, on the basis of the first trials and first calphadcalculations, presented in the mid term assessment report, some changes in composition will be proposed. In parallel, new alloys (such as AZ91E specially treated with Ca and Sr) will be tried. Aluminum automotive and aerospace demonstrator Casting of automotive and aerospace components was performed with standard alluminum alloys and innovative alloys from Pechiney. Parts with very complex geometry have been chosen, in order to investigate the process limits and possibilities. Optimised parameters were investigated, as well as alloy behaviour and final characteristics. automotive components: Suspension triangle, brake calliper; Aerospace component: Fitting hook About 30 parts per each alloy have been produced with good results in most of cases. Such components allow to demonstrate to possible customers the feasibility of complex, structural applications with the New Rheocasting process. Similar applications could start on the base of the project experience. life cycle assessment of the new technology LCA (Life Cycle Assessment) is a fundamental issue in developing a new technology. According to the experimental results, a complete analysis of the benefits in terms of processing and manufacturing with respect to other technologies will be accomplished. This will reveal opportunities for industrial production of rheocast components, taking into account the related environmental benefits with respect to the main competing technologies. CRF has a lot of experience and knowledge in this field: a special workgroup work every day in this field. The results given within the project on rheocasting and alternative processes will be the first complete study (from raw material to final component and end-of life component) that will be used as a basis for further technology study and development. LKR Numerical CALPHAD Approach of Aluminium 2024 Alloy in the semi-solid region.(Prediction of Semi-Solid Temperature at a given composition) When casting alloys in the semi-solid state with the New Rheocasting Process, usually a 50% solid fraction is located. Up to now, for each alloy a special temperature is given, at which the casting will take place, for instance about 580°C for A356, one of the most common alloys. For semi-solid casting it is very important that in the semi-solid range the alloy has a high tolerance in temperature so that for 1°C change the solid fraction changes just minimally, which is 1% for A356. However, with other alloys, the temperature tolerance is much lower, so that 1°C change produces up to 4% change in solid fraction. The New Rheocasting Process has a stability of about ±1,5 to 2°C, which would mean a change of maximal ±8% of solid. This would still work. However every alloy has a tolerance in its composition. But a change in element content changes also the solidification curve, as can be seen in the technical report. So it would mean that one casts at 65% solid while thinking of 50% solid fraction and therefore produces bad parts. An awareness of high tolerance intervals in alloys that change semi-solid temperature of given alloy with different composition makes one think of how to know the exact semi-solid temperature in order to ensure secure high-quality casting. There are expensive programs like Thermocalc or JMatPro that can do that, but this takes time and costs money. LKR now made numerical approximations based on the calphad approach for the alloys 2024, 356, 357 (Aluminium) and AM50 to AZ91 (Magnesium with Al, Mn, Zn Elements) in order to provide the cast shop with the necessary information. LKR Numerical CALPHAD Approach of Aluminium A356 A357 Alloys in the semi-solid region.(Prediction of Semi-Solid Temperature at a given composition) When casting alloys in the semi-solid state with the New Rheocasting Process, usually a 50% solid fraction is located. Up to now, for each alloy a special temperature is given, at which the casting will take place, for instance about 580°C for A356, one of the most common alloys. For semi-solid casting it is very important that in the semi-solid range the alloy has a high tolerance in temperature so that for 1°C change the solid fraction changes just minimally, which is 1% for A356. However, with other alloys, the temperature tolerance is much lower, so that 1°C change produces up to 4% change in solid fraction. The New Rheocasting Process has a stability of about ±1,5 to 2°C, which would mean a change of maximal ±8% of solid. This would still work. However every alloy has a tolerance in its composition. But a change in element content changes also the solidification curve, as can be seen in the technical report. So it would mean that one casts at 65% solid while thinking of 50% solid fraction and therefore produces bad parts. An awareness of high tolerance intervals in alloys that change semi-solid temperature of given alloy with different composition makes one think of how to know the exact semi-solid temperature in order to ensure secure high-quality casting. There are expensive programs like Thermocalc or JMatPro that can do that, but this takes time and costs money. LKR now made numerical approximations based on the calphad approach for the alloys 2024, 356, 357 (Aluminium) and AM50 to AZ91 (Magnesium with Al, Mn, Zn Elements) in order to provide the cast shop with the necessary information. technical comparison between rheo and thixo achievable properties The same component (a fitting hook of an aircraft cargo door locking system)has been studied during the previous ADFORM project, with thixocasting process, and the current RHEO-LIGHT project, with rheocasting process. In both cases, the microstructure, the mechanical characteritics (static, fatigue, damage tolerance)and the corrosion properties have been studied, making a direct comparison possible. Reduction of Lubrication for Demonstrator Part As every die casting method, New Rheocasting demands for lubricants in order for a non-sticking casting.There are water-based and oil based lubricants, and graphite, all with their advantages and disadvantages. However, there is an economical and ecological pressure to reduce lubricants for each casting.We showed with the Bosch Demonstrator Part, that we significantly could lower the amount of lubrication while still maintaining the non-sticking effect in near series production (60 parts in a row) Searching for OpenAIRE data... There was an error trying to search data from OpenAIRE No results available
