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AluminumPart and Component
ManufacturingTrends
GLOBAL DEMANDS
CHARAC-TERIZATION
CASTING
FORGING
EXTRUSION
ROLL FORMING
JOINING
ADDITIVE MANUFACTURING
MANUFACTURING
TECHNOLOGY
2
1 2 3
GLOBAL TRENDSTECHNOLOGY ROADMAP OF ALUMINUM
Currentstatus
Conventionallightweight
Moderatelightweight
Extremelightweight
Cold formingCasting
ExtrusionCold forming
Hot formingHydroforming
ExtrusionAdditive manufacturing
JoiningHot formingExtrusion
Additive manufacturing
PROCESSES
Tool designTechnology transfer
Material wasteHigh strength aluminum
High precision parts
Dissimilar materialsExtremely high strength aluminum
Surface qualityHigh precision parts
CHALLENGES
Adapted from Thailand Automotive Institute, 2018
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CASTING
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CASTINGTECHNOLOGY TRENDS
• Casting of complex geometries with integrated manifolds will need special core design
• Components are redesigned to reduce assembly steps
• Weldability materials with superior mechanical properties and microstructure
• Feasibility to join with other components (dissimilar joining, welding, and bonding)
High pressure die casting (HPDC)
• High strength-to-weight ratio• Alloying composition for stronger
materials• In-process microstructure control• Heat treatment
• Corrosion fatigues resistance• Load bearing components• Lack of endurance limit (some
alloys)• Corrosive environment leads to early
fatigues failure
• Intelligent process based on data analytic
Gravity casting
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CASTINGMTEC RESEARCH ACTIVITY
Simulation software for gating and feeding system
design
Squeeze castingReduction in number and pressure of air bubbles for weldability and
heat treatability
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CASTINGMTEC RESEARCH ACTIVITY
Database and SCADAfor casting process control
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CASTINGMTEC RESEARCH ACTIVITY
Inclusions in aluminum casting in Thailand
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CASTINGMTEC RESEARCH ACTIVITY
Effect of atmospheric conditions on corrosion fatigue
FORGING
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FORGINGTECHNOLOGY TRENDS
Load bearing components to replace Fe-based components
• Lack of experience in aluminum forging• Unpredicted mechanical properties
because of uncertain microstructure
Challenges
Extrusion
direction
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FORGINGMTEC RESEARCH ACTIVITY
xy
z
Temperature heat treated: 450 ºC Soaking time: 20 minCooling: Air
Cross section
Cross section
Microstructure observationof extruded billet
Observationdirection
Parallel to direction
Observationdirection
Perpendicular to direction
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FORGINGMTEC RESEARCH ACTIVITY
20 mm 20 mm
20 mm20 mm
Parallel to the ED Perpendicular to the ED
Extruded billetbefore heat treatment
Extruded billetafter heat treatment
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FORGINGMTEC RESEARCH ACTIVITY
500 µm 200 µm
100 µm 50 µm 50 µm
Effect of process parameters on component properties and microstructure
EXTRUSION
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EXTRUSIONMTEC RESEARCH ACTIVITY
Study of intermetallic phasetransformation mechanism
Observation of morphology change during heat treatment using synchrotron radiation
ROLL FORMING
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ROLL FORMINGAPPLICATIONS
Source: technologyinarchitecture.wordpress.comAdapted from Paralikas, I. N. , 2012
Aerospace industry• Airframe stringers and longerons• Interior components• Stiffeners• Jet engine components
Appliances industry• Refrigerator panels• Shelving, shell fronts• Decorative trim, handles• Back guard, rack-slide
Building/construction industry• Channels and angles• Metal roof decks• Sliding panels• Stiffeners and framing• Sliding doors
Automotive industry• Body-in-white structural parts• Closure frames (doors, hinges)• Seating track
Infrastructure• Structural beams• Joint beams• Barriers• Signing frames
Further applications• Elevator cages• Garage doors beams• Tubes and bars• Storage structures• Etc.
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Source: Chubu Engineering company
ROLL FORMINGCAPABILITY
Source: Paralikas, I. N. , 2012
Additional In-line Operation
Source: OMCO company
Punching Sweeps Notching Embossing
VSSteelRoll Forming
AluminumExtrusion
20Source: Zou, T., et al., 2016
ROLL FORMINGMTEC PAST ACTIVITY: ROLL PASS TRY OUT AND APPROVAL
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ROLL FORMINGBEYOND THE LIMITS
Tailor CoilRoll Forming
Varying Wall Thickness
Roll Forming3D Roll Forming
Source: Data M company Source: TWB company
Source: Welser company
JOINING
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JOININGAPPLICATIONS
Aluminum rolling stock
BIW structure
FSW liquid-cooled plate
Aluminum boat
Aluminum bus
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JOININGALUMINUM JOINING TECHNOLOGY
Source: Spinella, D., 2013
Fasteners&
Adhesives
Adhesives
Blind Fasteners
Solid Rivets
Bolts
Self Pierce Rivets
Clinching
Flow Drill Screws
MechanicalInterlock
ElectromagneticForming
Soldering
Dip
Furnace
Induction
Infrared
Iron
Resistance
Torch
Wave
Brazing
Atmosphere
Diffusion
Dip
Furnace
Infrared
Laser
Resistance
Torch
Solid-state
Cold
Cold Spray / Welding
Diffusion
Explosion
Friction
Friction StirSeam
Friction Stir Spot
Magnetic Pulse
Ultrasonic
Resistance
Resistance Spot
Weldbonding
Resistance Seam
Projection
High Freq Resistance
High FreqInduction
Flash
Upset, Pressure
Gas Tungsten-Arc (TIG)
Plasma
Electron Beam
Laser Beam
Laser Hybrid GMAW
RoomTemperature
450 °C 620°C and up(Above melting point)
Gas Metal-Arc (MIG)
Fusion&
Arc Welding
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Welding
Source: Gullino, 2019
Brazing
Source: Center for Automotive Research, 2017
Cladding
Source: Kattire, 2015
JOININGLASER JOINING TECHNOLOGY
Roll-plating (Bonding)
Source: Fraunhofer IWS, 2014Source: Kutsuna, 2010
Roll-welding
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JOININGCOMBINATION OF DISSIMILAR MATERIALS IN CAR STRUCTURES
Ford truck F-150 (2015)Aluminum bodySteel frame
Audi A8Audi Space Frame (ASF)Al + Mg + Steel + CFRP
2009 2018 Change
40.50%
(17% PHS)
Aluminum 92% 58% -34.00%
Other
materials
- 1.50% 1.50%
Steel 8% 32.50%
The right materialin the right place and in the right amount
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JOININGLASER WELDING AT MTEC
Dissimilar joining6kW fiber laser
• High precision and consistency
• Complicated joining• High strength with high depth weld
• Less damages from excess heat and contact
Advantages
Work in collaboration with Osaka university (JWRI)
• Joining of metallic foam and solid sheet
Preventing damages at metallic foam by excessive heat
• Direct joining of titanium and polyamide by laser radiation
Enhanced joint strength by modifications of Ti oxides layer
New joining techniques
TitaniumPolyamide
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JOININGLASER WELDING AT MTEC
Dissimilar joining between aluminum alloysand high strength steel (780Y)
Steel
Al
Shear tensile strength of the joint > 300 MPa
Small spot (400 µm) fiber laser was applied in zigzag patterns to produce sufficient joining area for load bearing.
Joining of aluminum and polyamide6
ADDITIVE MANUFACTURING
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ADDITIVE MANUFACTURINGMTEC TECHNOLOGY ROADMAP
Direct Energy Deposition Powder Bed Fusion
Source: lightmetalage.com
aluminum fuselage panelSource: 3dprintingindustry.com
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ADDITIVE MANUFACTURINGWIRE-BASED ADDITIVE MANUFACTURING (WAM)
Wire materialsLow prices
Widely availableMinimized inventory space
Large-scale component printingRobotic-controlled productionNo vacuum chamber required
Mechanical propertieswith shorter lead time (10 kg/hrfor steel)
Machine developmentbased on MTEC’s broad expertise in welding and robot system
Cost savingLower production costs for small batch production
Example: Nickel-chromium steel component
Cost is reduced from 160,000 to 70,000 THB
Advanced component designMulti-material components for tailored properties
WhyWAM?
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ADDITIVE MANUFACTURINGWIRE-BASED ADDITIVE MANUFACTURING (WAM)
KEY FEATURES
Fast printing speedCost saving
Aluminum alloy wire choices include 1100, 2024, 2318, 2319, 3000 series, 4043, 4047, 5087, 5183, 5356, 5554, and 5556.
Source: ramlab.com
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ADDITIVE MANUFACTURINGWIRE-BASED ADDITIVE MANUFACTURING (WAM)
ON-DEMAND INDUSTRIAL REPLACEMENT
Business opportunities: Industrial parts
Real-time process monitoring
Adaptive printing strategies
CAE-based design
Possibilities for AI integrated algorithms
Material characterization
Optional post-processing for enhanced properties
Energy industry
Oceanic/offshoreindustry
Source: mx3d.com
Source: 3dprintingindustry.com
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Material developerNew material for AMApplication-based alloying for AM
Technology consultantApplication-basedprocess selection
Material expertAM part reliability testing
Post-processing guidelinesSurface treatment for AM
Technology developerNew wire-AM systemPrinting strategy optimizerThermal stress prediction
Solution providerAM cost/benefit analysisComponent design
ADDITIVE MANUFACTURINGMTEC EXPERTISE
MATERIAL CHARACTERIZATION
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Charac-terization
• From sub-atomic to macro structure
• Microscopy or Spectroscopy
• Mechanical properties• Chemical properties
• Electrical properties• Thermal
properties
• Casting• Powder
Processing• Bulk Deformation
MATERIAL CHARACTERIZATIONMATERIALS PARADIGM
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MATERIAL CHARACTERIZATIONX-RAY COMPUTED TOMOGRAPHY (X-RAY CT)
Source: Xu et al., 2019
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Source: Villarraga-Gómez et al., 2018
Inconel and Al powder for additive manufacturing
Source: Jeon et al., 2010
Al foam and internal pore structure
MATERIAL CHARACTERIZATIONX-RAY MICRO CT APPLICATIONS
Image-basedfinite element analysis
Internal featuresand inclusions
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• Surfaces• Reverse engineering• Metrology: shape, size, thickness and dimensions• Nominal/actual shape-size comparison
1mm 1mm
As-printed Polished
Source: Kerckhofs et al., 2012
Additively manufactured Ti64 Part to CAD comparison of flexure
Source: Villarraga et al., 2015
MATERIAL CHARACTERIZATIONX-RAY MICRO CT APPLICATIONS
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FREE seminar
3D Micro CTfor Non-destructive Material Characterization
(Conducted in English)
Location: MR214 Room, BITECDate: 22 November 2019
Time: 9:30 – 12:00
Please RSVP at
