Toyota Boasts About Castings

Taken from http://www.moderncasting.com/

Before the big game this past weekend, we saw some castings while watching the NFL during championship week. (Are we getting paid for this overtime?) The castings weren’t on the field of play, of course (although the Steelers defense often looks like it’s composed of engineered metal components). Instead, they took center stage in an advertisement for the Toyota Tundra.
In the 30-second spot, Toyota highlights the Tundra’s power train. On the right side of an oversized balance is a “cast iron V-8 block [that] makes your truck weigh more,” and on the left is an “aluminum [block] that lets you tow more.”

The announcer doesn’t say so, but of course the block on the left is also cast. According to marketing representative Erin Poole, the part is in fact made by Toyota-owned metalcasting facility Bodine Aluminum. Regardless of the use of the word “cast” with the iron block but not the aluminum one, both of the parts are intended in the commercial to look like mean components that make up a mean machine. And the engineered, cohesive look of the castings helps pull that intention off.

Remember, this is the line of trucks that have been featured in some of the more over-the-top truck advertisements ever produced. Namely, the ones showing the Tundra pulling off death defying feats with relative ease—bringing a 10,000-lb. trailer quickly to a stop down a steep grade, stopping at the edge of a gorge after barreling through a tight gate, etc. The company also went all out to show just how tough the Tundra is during this year’s Super Bowl. So the castings used in the more subtle campaign have big shoes to fill.

And according to Poole, castings haven’t made their last appearance in the Tundra commercials. The truck also features a cast steel brake rotor that will make an appearance in the campaign sometime in the near future. Keep yours eyes out for it, and tell your boss you did some industry research while watching TV.

Parts Cast in a New Light

By Rebecca Thyer

Special coating gives auto plants a competitive edge.
An Australian discovery is revving up the world's car parts industry by radically advancing the performance of component casting. Through work to develop a long-life die coat for the low-pressure and gravity die casting industry, a revolutionary new insulating coat has been developed that can last up to 10 times longer than traditional coatings.
Dr Mahnaz Jahedi and Stefan Gulizia with a BMW V8 Engine Block made in the European trial of CASTcoat™

CASTcoat™ is an ultra-low maintenance coating with adaptable insulating properties. The coating – essentially a strong, porous ceramic layer that is resistant to wear and tear – is applied to the die using a thermal spraying technique. (A die is a mould in which metal components are formed.)

CSIRO scientists Dr Mahnaz Jahedi and Stefan Gulizia, and a University of Queensland PhD student, Mary Giannos, initially discovered CASTcoat™. The CSIRO scientists then developed the technology for an industrial environment. The research program was part of the Cooperative Research Centres for Cast Metals Manufacturing (CAST), giving the product its name.
In conventional low pressure and gravity die casting processes, filling the die cavity is slow and the metal die has the capacity to rapidly extract heat from the molten alloy. Traditionally, die coats act as insulators to prevent premature solidification of the casting, but they also control the quality of the end product.

While these coatings provide adequate insulation and prevent premature solidification of the alloy, they offer poor resistance to wear, because of weak bonding. Their application is also highly operator-dependent. It is not uncommon for coatings to be completely replaced after a few shifts. Even after only a few uses or 'shots', localised damage on the coating surface in the die cavity often needs to be repaired, a process called ' touch ups'.

Leading CSIRO Manufacturing and Infrastructure Technology researcher Dr Mahnaz Jahedi says this has been a long-term problem for industry: 'Consistency of parts could not be guaranteed.'

CASTcoat™ overcomes traditional problems because of its use of thermal spray technology. Instead of using a silicate-based binder, bonding is created by partial melting of the actual ceramic particles, fusing them together.

The resulting bond is far stronger than traditional binders. This means high wear-resistance and durability, ensuring the die is better protected, with none of the constant touch-ups required by conventional die coats.

In a current European trial, a car parts producer that supplies well-known automotive manufacturers has been 'overwhelmed' by the results.
Dr Jahedi says the company applied CASTcoat™ before Christmas and by the second week of January it still had not needed replacing: ' Using conventional methods, the insulating coat would have been replaced many times by then.'

Successful industry trials have now led to the commercialisation of CASTcoat™ by Acheson Industries (part of the ICI group), which has taken up an exclusive licence for the technology.
Jean-Michel Bachtarzi, Acheson global business director process and engineering materials, says: 'We have evidence that the current CASTcoat™ performance delivers tangible and significant benefits that help the industry meet its objectives. CASTcoat™ provides Acheson with a revolutionary new technology that creates significant market opportunities for our company.'

Additionally, the insulating properties of CASTcoat™ can be tailored to any application, without changing the die coat thickness, while product consistency can be ensured.
A wide range of casting surface finishes – from rough to very smooth – can also be produced by CASTcoat™ and maintained.

While the main users will be companies that manufacture lightweight allow parts for the automotive industry, the durable insulating coat can be used across a variety of applications, such as molten metal handling or wherever any insulating and wear-resistant coatings are needed, says Dr Jahedi. 'There have been a lot of enquiries from companies wanting to use this technology.'

CAST was established under the Australian Government's CRC program and has backing from the Victorian and Queensland state governments.

New aluminum selected for Ferrari S.p.A.

Alcoa Wheel and Transportation Products, Cleveland, Ohio, announces that it has been selected by Ferrari S.p.A. to supply the all-aluminum spaceframe for the upcoming Ferrari California sports car. The strength and lightweight advantages of aluminum allow Ferrari to maximize performance, strength, and structural rigidity. Learn more.

ALUMINUM MASTER ALLOYS AND ADDITIVES “THE MAGIC INGREDIENTS”

The U.S. Aluminum Industry is the world’s largest, producing about 20 billion pounds of metal annually. The industry employed 141,000 people with an annual payroll of $5.2 billion and shipped $38.8 billion in products in 2000. The high quality of these products and the profitability of the industry are due, in large part, to the contributions of a niche industry made up of the Master Alloys and Additives companies. These companies have dedicated their efforts to providing the Aluminum Industry with special alloys and additives that reduce manufacturing cycle time and enhance product quality. Some of their contributions to the aluminum industry are presented below.

http://www.aluminum.org/Content/NavigationMenu/TheIndustry/MasterAlloys/default.htm

Bruker AXS Expands Instrumentation Product Line for Die Casting Analysis with World's First Handheld XRF to Include Silicon Drift Detector

Bruker AXS announces another technology breakthrough for the die casting industry with the introduction of its new TRACERturboSDTM, the world's first handheld X-ray Fluorescence (XRF) instrument that uses a Silicon Drift Detector (SDD) for dramatically improved speed, sensitivity and resolution. Bruker's industry-leading proprietary XFlashTM SDD, previously available only in high-performance laboratory XRF instruments, now offers unprecedented speed and analytical specificity when integrated into the novel handheld TRACERturboSD
With this announcement, the Bruker AXS Handheld business, until recently known as Keymaster Technologies Inc., builds on its long tradition of technology leadership in the handheld XRF industry that includes:

2001 - First tube-based handheld XRF
2004 - First vacuum handheld XRF, co-invented with NASA
2008 - First SDD-based handheld XRF

The revolutionary TRACERturboSD with integrated SDD offers unparalleled speed, sensitivity and energy resolution, previously found only in more expensive laboratory systems. Now all handheld XRF customer segments can benefit from these compelling performance advantages in their analytical work. In the aerospace metals industry, the proprietary Bruker SDD technology enables TRACERturboSD users to better and faster analyze sophisticated light element alloys, even without the use of a vacuum or helium attachment. In the general metals analysis markets, the Bruker TRACERturboSD offers higher speed, sensitivity and selectivity for many demanding handheld XRF applications.

This detector provides a major improvement in the analytical performance of handheld alloy analyzers. The measurement precision is improved by a factor of two to three times, in addition to making the measurement of light elements such as Mg, Al and Si possible when operating in air mode. The TRACERturboSD provides a new capability of measuring aluminum in titanium alloys and magnesium and silicon in aluminum alloys, with no vacuum or helium required. For additional sensitivity, the well-known joint Bruker-NASA vacuum technology can be combined with the SDD to provide the best sensitivity possible in a handheld XRF instrument.

The TRACER turboSD includes all of the standard features of the highly-regarded Bruker S1 Tracer analyzer, such as Grade ID and chemistry, a unique PASS/FAIL analysis capability and the largest Grade library in the industry. The capabilities of the TRACERturboSD make it the ideal analyzer for the measurement of all types of alloys. In addition to the new high-end TRACERturboSD, Bruker AXS continues to offer the standard S1 TracerTM handheld instrument with traditional SiPIN diode technology for routine analysis

John Landefeld, Vice President of Bruker AXS Handheld, stated: "This breakthrough continues our tradition of technology leadership, going back to the initial introduction of tube-based XRF handhelds in 2001. Following the joint NASA-Bruker development of vacuum technology for handhelds in 2004, Bruker proves, once again, to be the overall technology leader in handheld XRF instrumentation, especially in the metals industries."

"The die casting industry will be particularly pleased to find that high-end handheld XRF can now approach the capabilities of laboratory systems," added John Patterson, Director of Marketing and Product Management of Bruker AXS Handheld.
For more TRACERturboSD information, please visit: www.bruker-axs.com/handheld.

Heat treatment for diecast parts supplies stronger castings

High pressure diecasting (HPDC) is one of the most cost-effective process for making large quantities of complex aluminum components in netshape. But while other cast aluminum parts can be heat treated to improve their mechanical properties, this had not been possible for many die castings.

[ILLUSTRATION OMITTED]

Australia's Commonwealth Scientific and Industrial Research Organization's (CSIRO) Light Metals Flagship has developed a new heat treatment process for strengthening aluminum HPDC parts.

Standard die castings contain trapped gas pores that expand, blister and distort the casting when conventional heat treatment is applied, making the parts unusable. Previous attempts to make them heat-treatable have focused on removing porosity from the cast parts. But Flagship researchers developed a process that did not depend on reducing porosity, and they successfully tested the technology on large batches of parts purchased from the industry.

[ILLUSTRATION OMITTED]

"Components treated with the new process do not show surface blistering or dimensional changes," said Roger Lumley, metallurgist for Light Metals Flagship. "They retain an as-cast appearance." The process doubles the strength of parts made from the common diecast aluminum alloys. The heat treated components exhibit fatigue resistance as high as some wrought aluminum products and thermal conductivity about 20% above the as-cast status, meaning that for engine or transmission applications, heat can be transferred or removed more efficiently and quickly. This could mean that HPDC parts would operate with lower amounts of fluid in cooling and lubrications systems.

The new heat treating process also may substantially raise energy absorption during fracture when heat treated for this purpose, which has significant implications for crash-sensitive structural components. For example, one common secondary alloy almost doubled in energy absorption when heat treated for that purpose. "We envisage that this will make it possible to use HPDC components more widely in load carrying structural and safety applications," Lumley said. The heat treating process is designed to be implemented in existing manufacturing facilities using conventional heat treatment equipment, such as continuous belt furnaces, fluidized beds or furnace systems designed specifically for rapid heat treatment.

After the success of the trials for HPDC parts up to 66 lbs. (30 kg), the Light Metals Flagships is looking for companies to collaborate on developing lightweight products through component design and implement the new procedures in the diecasting industry.

Visit http://www.csiro.au/ for more information.

"Heat treatment for diecast parts supplies stronger castings" The Free Library 01 March 2008. 20 May 2008 <http://www.thefreelibrary.com/Heat treatment for diecast parts supplies stronger castings.-a0177175205>.

ALCAN COMPACT DEGASSER

IMPROVED METALLURGICAL UNDERSTANDING OF THE ALCAN COMPACT DEGASSER AFTER TWO YEARS OF INDUSTRIAL IMPLEMENTATIONIN ALUMINUM CASTING PLANTS

Peter D. WaiteAlcan International LimitedArvida Research and Development Centre1955 Mellon Blvd., P.O. Box 1250Jonquike, Quebec, Canada G7S 4K8

Abstract Over the past two years, industrial implementation of the Alcan compact degasser has continued, and it is presently being used inmore than half a dozen casting facilities. During this period, further quantification of the process metal treatment efficiency has been undertaken for a wide range of alloys and casting conditions. The extensive plant data that has been collected was analyzedusing the underlying metallurgical principles as guidelines. This has led to an improved understanding of the ACD specifically, and of multi-stage in-lint treatment processes in general. The relationship between the metallurgical principles used for data analysis and the dcgasser metal treatment performance arediscussed, and factors affecting hydrogen removal performance were identified. Examples illustrating these findings are presented using plant data for the Alcan compact degasser and for conventional in-line degassers.

Grain Refinement of Aluminum Casting Alloys

Grain Refinement of Aluminum Casting Alloys, G. Sigworth and T. Kuhn

The mechanisms and benefits of grain refinement are described.

Abstract

An overview is given of grain refinement in aluminum casting alloys. The mechanisms involved and the benefits of refinement are described. The review shows that current practices were developed long before modern Al-Ti-B refiners became available, and are employed now largely for historical reasons. The results of tests in Al-Si, Al-Si-Cu, Al-Cu, Al-Mg and Al-Zn-Mg alloys are presented. The grain refining response is different for each alloy system. It is important to
understand that titanium can be present in two forms. One dissolves in aluminum; the other is nearly insoluble. Each must be controlled separately. With today's powerful Al-Ti-B refiners, there is no reason for large additions of soluble titanium in most alloys. In fact, it is better to say we grain refine with boron, not titanium. The recommended addition is 10-20 ppm of boron, preferably in the form of Al-5Ti-1B or Al-3Ti-1B rod. Lower dissolved titanium levels provide better grain refinement and an improved resistance to hot cracking in some alloys. Al-Si casting alloys which contain copper are an exception. In alloys such as 319 or 355, it is best to have a minimum of about 0.1 % Ti.

AFS Transactions 2007 © American Foundry Society, Schaumburg, IL USA

Yamaha to introduce DiASil cylinder in India

Parallel to a slew of launches, Yamaha Motor India is aiming to demonstrate its technological prowess with the launch of DiASil Cylinder in the Indian market. Yamaha “DiASil Cylinder” is used on the new 150cc YZF-R15 which was unveiled at Auto Expo 2008 and will be released in the market later this year.

Developed in 2002 by Yamaha Motor Co., Ltd, Yamaha “DiASil Cylinder” is an all-aluminum die-cast cylinder with 60% better cooling performance and 30% cheaper production cost than a conventional cylinder. Yamaha “DiASil Cylinder”, is the world’s first all-aluminum die-cast cylinder and it achieves cooling performance equivalent to that of a nickel-plated cylinder, which is currently recognized as the best in the industry, but at a significantly lower production cost than a nickel-plated cylinder.

“DiASil", an abbreviation for "Die-casting Aluminum-Silicon", is a technology which brings together an ideal combination of material, manufacturing technology and environmental friendliness. The material used is a 20% silicon content aluminum alloy, the manufacturing technology is the Yamaha CF Aluminum Die-cast Technology, which enables the production of an all-aluminum die-cast cylinder. It is Yamaha’s exclusive CF Aluminum Die-cast Technology that enables the mass production of a die-cast cylinder made completely of 20% silicon content aluminum alloy, something that could not be done with conventional die casting methods.

According to Mr. Sanjay Tripathi, Head of Dept- Product Planning & Strategy, “Conventional engine cylinders have a steel liner to reduce the friction resulting from the piston's movement. The "DiASil" cylinder is made by the exclusive Yamaha Aluminum Controlled Forging (CF) technology. Because the "DiASil" Cylinder is all aluminum, it has excellent heat dissipation qualities and reduces engine weight at the same time. In comparison to cast steel liner type aluminum cylinders, the DiASil cylinder has 60% better cooling performance at 30% lower manufacturing cost and enables 30% lighter design which results in better power to weight ratio besides excellent recyclability”.

“Considering the environment-friendly nature of aluminum, we have made aluminum technologies part of our core technology and actively increasing the use of aluminum in our products. Our CF Aluminum Die-cast Technology enables the mass production of die-cast aluminum parts that are both thinner and larger than was possible in the past. This same technology has been applied to the manufacture of engine parts. This is also a technology that can be easily transferred to overseas Yamaha manufacturing bases. Yamaha also plans to apply to new areas automobile and outboard motor engine parts”, he added.

This next-generation technology promises to contribute to improved function and product quality for the majority of Asian market motorcycles and automobiles that presently use conventional pistons with cast steel liners.

Sourced From: Mavcomm Consulting Pvt Ltd

Grain refinement of aluminum casting alloys

Website Only Article: Grain Refinement of Aluminum Casting Alloys

G. Sigworth
Alcoa Primary Metals, Rockdale, Texas

and T. Kuhn
Alcoa Primary Metals, Frederick, Maryland


The mechanisms and benefits of grain refinement are described. Downloadable from AFS site

Abstract

An overview is given of grain refinement in aluminum casting alloys. The mechanisms involved and the benefits ofrefinement are described. The review shows that current practices were developed long before modern Al-Ti-B refinersbecame available, and are employed now largely for historical reasons. The results of tests in Al-Si, Al-Si-Cu, Al-Cu, Al-Mgand Al-Zn-Mg alloys are presented. The grain refining response is different for each alloy system. It is important tounderstand that titanium can be present in two forms. One dissolves in aluminum; the other is nearly insoluble. Each must becontrolled separately. With today's powerful Al-Ti-B refiners, there is no reason for large additions of soluble titanium inmost alloys. In fact, it is better to say we grain refine with boron, not titanium. The recommended addition is 10-20 ppm ofboron, preferably in the form of Al-5Ti-1B or Al-3Ti-1B rod. Lower dissolved titanium levels provide better grainrefinement and an improved resistance to hot cracking in some alloys. Al-Si casting alloys which contain copper are anexception. In alloys such as 319 or 355, it is best to have a minimum of about 0.1 % Ti.

Aluminum alloy for producing high performance shaped castings

Abstract

An aluminum alloy for shaped castings, the alloy having the following composition ranges in weight percent: about 6.0–8.5% silicon, less than 0.4% magnesium, less than 0.1% cerium, less than 0.2% iron, copper in a range from about 0.1% to about 0.5% and/or zinc in a range from about 1% to about 4%, the alloy being particularly suited for T5 heat treatment.

• Patent number: 7087125


• Filing date: Jan 28, 2005


• Issue date: Aug 8, 2006


• Inventors: Jen C. Lin, Cagatay Yanar, Wenping Zhang, Pål S. Jacobsen, Geir Grasmo, Michael K. Brandt, Moustapha Mbaye, Martijn Vos, Michael V. Glazoff, Knut Pettesen, Svein Jorgensen, Terje Johnsen


• Assignee: Alcoa Inc.


• Primary Examiner: George Wyszomierski


• Secondary Examiner: Janelle Morillo


• Attorneys: Greenberg Traurig LLP, Harry A. Hild, Jr.Application number: 11/045,845

Download this patent from Google

Image from http://www.flickr.com/photos/11012311@N07/2143283661/

Wear behaviour of cast hypereutectic aluminium silicon alloys

Wear behaviour of cast hypereutectic aluminium silicon alloys

Dheerendra Kumar Dwivedi

Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee 247 667, India

Abstract

In the present paper, influence of alloying elements on wear behaviour of binary (Al–17%Si) and multi-component (Al–17Si–0.8Ni–0.6Mg–1.2Cu–0.6Fe) cast hypereutectic aluminium alloys has been reported. Experimental alloys were prepared via foundry technique. Wear behaviour of Al–17Si and Al–17Si–X {X = Ni, Cu, Mg, Fe} alloys was studied using pin on disc (ASTM: G99) type of friction and wear testing machine. Dry sliding wear tests were performed at various sliding speeds (0.2–4.0 m/s) and contact loads (10–30 N) against hardened ground steel disc (hardness 60 HRC). It was observed that the addition of alloying element not only reduces the wear rate in mild oxidative wear condition but also increases the transition load. Temperature of wear pin near the sliding surface was measured and it was related to wear and friction behaviour of experimental alloys. Increase in hardness was also noticed due to alloying. SEM study of wear surface and wear debris was conducted to analyse the mode of wear and wear mechanism.

doi:10.1016/j.matdes.2004.11.029

Residual stresses in aluminum castings

Residual stresses in aluminum castings

J.E. Wyatt, J.T. Berry, and A.R. Williams

Abstract

The majority of manufacturing processes induce residual stresses in the surface of the component produced. These residual stresses can be either beneficial or in some cases detrimental to the performance of the component in question. This investigation involves the use of a previously described new low-cost method to determine the superficial residual stresses in a casting of A356 aluminum alloy. The technique concerned involves the measurement of the change in spacing of previously applied pairs of micro-hardness indentations which occurs upon stress relief. In the case of a compressive residual stress, this spacing will increase after stress relief. In estimating the strain concerned it should be noted that the equivalent ‘original gage length’ will be the relaxed spacing measurement. This strain multiplied by the modulus of elasticity will indicate the corresponding stress for a uniaxial stress state. The special 3 bar test frames that were employed had their residual stresses measured using both a cutting and a thermal stress relief technique. From the results it can be seen that the use of cutting is probably applicable to the more localized stresses that occur in the vicinity of the cutting zone. However, the stresses that remain in the frame redistribute themselves to maintain equilibrium, and are not measurable until the cut frame is stress relieved thermally. It was noted that the levels of strain measured were unusually high. This may be related to the occasional spontaneous failure of the castings on removal from their molds. The current paper describes the results of on-going research in this area.

doi:10.1016/j.jmatprotec.2007.03.018

New book on Aluminum Casting

Casting Aluminum Alloys

By Vadim S Zolotorevsky, Nikolai A Belov, Michael V Glazoff

Product Description
This monograph summarizes research conducted at Moscow Institute of Steel and Alloy during many decades in part together with Alcoa Inc. The research covered areas of the structure, properties, thermal resistance, corrosion and fatigue of aluminum alloys in industrial manufacturing.· Emphasis on interconnection among phase equilibria, thermodynamics and microstructure of alloys;· Systematic overview of all phase diagrams with Al that are important for the development of casting aluminium alloys· Diagrams ("processing windows") of important technological properties such as castability, molten metal fluidity, tendency to hot pre-solidification cracking, porosity· Mathematical models for alloy mechanical properties facilitating the down-selection of best prospect candidates for new alloy development · New principles of design of eutectic casting aluminium alloys· Examples of successful novel casting alloy development, including alloys for high-strength applications, alloys with transition metals, and novel alloys utilizing aluminium scrap

Product Details
Published on: 2007-10-08
Number of items: 1
Binding: Hardcover
544 pages