THIN-WALLED DIE CASTINGS FOCUS OF NATIONAL RESEARCH PROJECT
Development of vacuum diecasting and a materials engineering model is underway to achieve thin-walled aluminum parts without sacrifi cing strength.
L AN MCDP STAFF REPORT
ighter, stronger aluminum components is the ultimate goal in a recently started research project that joins industry, research and academic institutions to develop innovative manufacturing solutions and transfer them into real-world production. In August, Lightweight Innovations for Tomorrow (LIFT) announced a new project intended to advance
technologies for diecasting and heat treating aluminum parts, primarily for aero- space, defense and automotive applications. “If we can reduce just a few ounces of metal from automobile engine mount-
ing cradles or the housings that hold transmissions, we can deliver an impact that is multiplied by the millions,” said Larry Brown, executive director, LIFT. “In aerospace, an added benefi t might lower manufacturing costs as well as increase fuel savings from the lighter weight designs.” LIFT is operated by the American Lightweight Materials Manufactur-
ing Innovation Institute and is one of the founding institutes in the National Network for Manufacturing Innovation, which is a federal initiative to create regional hubs to accelerate the development and adoption of cutting edge manufacturing technologies. It was formed in 2014, and the vacuum diecast- ing project is one of the first two started. The other project focuses on thin- walled gray iron parts. Lead partners for the project are Boeing and T e Ohio State University. T e focus is to develop key process technologies (super vacuum diecasting and
a shortened heat treatment) and computer engineering tools for 300 series aluminum diecasting alloys to improve mechanical properties and reduce the minimum wall thickness (up to 40%) and weight (up to 20%). According to Alan Luo, professor of materials science and engineering and integrated systems engineering, T e Ohio State University, the project will reduce the variability in quality and improve the mechanical properties of high pressure die castings. T e project also will explore new design methods of lightweight castings using local mechanical properties predicted by the new computer engineering tools, as opposed to the current casting design using minimum properties of cast alloys. “If you can take a common part,
such as an access panel you see on the wing of an airplane and use high
Nov/Dec 2015 | METAL CASTING DESIGN & PURCHASING | 23
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