Il Progetto StaCast: Nuovi Standard per la qualità e la progettazione di prodotti in lega di alluminio

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1 Il Progetto : Nuovi Standard per la qualità e la progettazione di prodotti in lega di alluminio Franco BONOLLO, 1 Project Scenario delle Fonderie EU CAEF: Foundry industry is a key-sector in EU production. Ferrous castings: mill. tons in 2010, 2000 companies, employees, Non-ferrous castings: 3.24 mill. tons in 2010, 2850 companies, employees. Suppliers (materials, technology, engineering services, consumables): at least similar size, in terms of numbers of companies and of employees. 2 1

2 Project Aspetti-chiave ruolo strategico delle leghe di Alluminio per il futuro dell industria EU delle fonderie necessità di standard per identificare i difetti nei getti in lega di alluminio necessità di standard per valutare il comportamento meccanico delle leghe di Al da fonderia necessità di regole ingegneristiche per la progettazione meccanica di getti in lega di Al 3 Project Leghe di Al: strategiche 4 2

3 Project Standard la classificazione dei difetti 5 Project Standard la classificazione dei difetti 6 3

4 Project Percorso per uno Standard EN sui Difetti 7 Project Percorso per uno Standard EN sui Difetti I) morfologia/localizzazione difetti (interni, esterni, geometrici) II) Origine metallurgica dei difetti (es: porosità da gas, ritiro di solidificazione, ecc.) III) Tipo specifico di difetto (lo stesso fenomeno metallurgico può produrre diversi difetti) 8 4

5 Project Percorso per uno Standard EN sui Difetti - scheduling for the development of a related CEN Workshop of Agreement (CWA), including timetable for meetings and approval of it, will be elaborated and included in Deliverable D1.2 (Month 6), - elaboration and submission to CEN of the CWA, which will be associated to Milestone MS7 (Month 12) and Deliverable D2.3 (Month 15). 9 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 10 5

6 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 11 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 12 6

7 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 1st Level 2nd Level A1 A2 3rd Level Shrinkage defects Gas-related defects A Internal defects A3 A4 A5 Filling-related defects Undesired phases Thermal contraction defects A1.1 Macro-shrinkage A1.2 Interdendritic shrinkage A1.3 Layer porosity A2.1 Air entrapment porosity A2.2 Hydrogen porosity A2.3 Vapour entrapment porosity A2.4 Lubricant entrapment porosity A3.1 Joint A3.2 Lamination A3.3 Cold shot A4.1 Inclusion A4.2 Undesired structure A5.1 Crack A5.2 Hot tear 13 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti st 1 Level 2 Surface defects rd Level 3 Level Shrinkage defects B1.1 Sink B2 Gas-related defects B2.1 Blister B3.1 Joint and Vortex B3.2 Lamination B3.3 Cold shot B4.1 Surface deposit B4.2 Contamination or inclusion B5.1 Crack B5.2 Hot tear B6.1 Erosion B6.2 Soldering B6.3 Thermal fatigue B6.4 Ejection mark B6.5 Corrosion of the die B3 B nd B1 B4 B5 B6 Filling-related defects Undesired phases Thermal contraction defects Metal-die interaction defects 14 7

8 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti st nd 1 Level C Geometrical defects 2 rd Level 3 Level C1 Lack of material C1.1 Incomplete casting C2 Excess of material C2.1 Flash C3 Out of tollerance C3.1 Deformed part 15 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 16 8

9 First draft of CEN Workshop of Agreement on defects classification Project Percorso per uno Standard EN sui Difetti 17 Project Standard per il comportamento meccanico NADIA New Automotive components Designed for and manufactured by Intelligent processing of light Alloys 18 9

10 Project Standard per il comportamento meccanico Alloy Numerical designation UTSmin (MPa) YSmin (MPa) elongation Hardness [%] [HB] 19 Project Standard per il comportamento meccanico - scheduling for the development of a related CEN Workshop of Agreement (CWA), including timetable for meetings and approval of it, will be elaborated and included in Deliverable D1.2 (Month 6), - elaboration and submission to CEN of the CWA, which will be associated to Milestone MS8 (Month 12) and Deliverable D3.3 (Month 15)

11 Project Regole di Progettazione 308 MPa, 3.6% EN 1676 Increasing Area Fraction of Defects Quality Index true 755 ( pl ) Project Regole di Progettazione 22 11

12 Project Regole di Progettazione gli aspetti microstrutturali possono essere previsti sulla base dei tempi di solidificazione calcolati mediante la simulazione numerica il contenuto di difetti può essere valutato mediante di criteri di qualità forniti dalla simulazione la distribuzione effettiva delle proprietà meccaniche può essere ragionevolmente ottenuta implementando negli strumenti di calcolo le relazioni processo-microstruttura-proprietà ricavate sperimentalmente 23 Project Regole di Progettazione 24 12

13 Project Regole di Progettazione 25 Project Regole di Progettazione -definition of structure and contents of Guidelines and Rules, including timetable for meetings and work organisation, will be agreed and included in Deliverable D1.2 (Month 6), -elaboration of draft version of Guidelines and Rules, associated to Milestone MS9 (Month 15), which will be validated on an industrial and application basis, -elaboration of final and public version of Guidelines and Rules, associated to Deliverable D4.1 (Month 18)

14 Project Struttura WP1: Focussing Standardisation needs WP2: New EU Standard WP3: New EU Standard on Defects classification in Al alloy castings on Mechanical Properties of Al foundry alloys WP4: New guidelines for mechanical design of Al alloy cast components WP5: Dissemination and Public Reporting on proposed Standards and Guidelines WP6: Project Management 27 Project Struttura 28 14

15 Project Il Consorzio 29 Project Ruolo dei Partners Participant Number Participant Organisation Name Type Organisation 1 DTG University Dept. 2 GTA University Dept. 3 NTNU University Dept. 4 AIM Industrial Association 5 ASSOMET servizi srl 6 FACE SME, member of Italian Standardisation board (non-ferrous alloys) Federation of Aluminium Consumers Role in the project Co-ordination, Data collection and elaboration in view of standards and guidelines (focus on defects vs mechanical properties correlations) Co-ordination, Data collection and elaboration in view of standards and guidelines (focus on high pressure die cast components and related mechanical properties) Co-ordination, Data collection and elaboration in view of standards and guidelines (focus on gravity die cast components and related defects and mechanical properties) Support, as Industrial Association, to data collection and to dissemination of project results Organisation of the elaborated data and information according to standard structure, interaction with CEN Al alloys Committee Support, as EU Federation of Consumers, to data collection and to dissemination of project results 30 15

16 Project Impatto Italy Country Germany Italy Spain Sweden Germany France Poland 245 n.a UK EU ~ 2550 ~ * Project Impatto 32 16

17 Project Impatto Quality controls Raw Materials and Consumables income Melting Al alloys: Supplier certificates + spectrometer analysis Die inserts: Sample validation & control Spectrometer analysis Spectrometer analysis on alloy samples taken from maintenance furnace Casting shot parameters by HPDC machine shot-control Radiographic inspection on castings Gauges and visual control by operator Quality controls as defined by Control Plan Insert detectors (periodically) Visual control by operator Gauges and visual control by operator Quality controls as defined by Control Plan Leak tests 3D controls Final controls as defined by Control Plan HPDC Casting + trimming Shot Blasting Machining Washing and Packing Avg time after casting no yes yes yes no yes yes yes yes yes yes seconds hours minutes hours hours days days days days days days Scrap detection Production flow 33 Project Impatto Consideando che la percentuale di scarti può mediamente variare tra il 5 e il 15%, si può stimare che ogni anno in Europe tonnellate di alluminio vengono fuse e colate solo per produrre scarti! Nuovi standard, focalizzati sulla qualità, aiuteranno le fonderie a ridurre i costi della non-qualità, e ad accrescere la loro competitività. Ogni azione in termini di riduzione degli scarti significa istantaneamente una riduzione nei consumi energetici. Il nuovo standard EN sulla classificazione dei difetti rappresenta una reale azione strutturale per aumentare la qualità dei prodotti di fonderia

18 Project Impatto Kind of Company Impact expected by - Engineering companies Alloy producers Foundries - End-users (e.g. automotive companies) Reliable data on mechanical behaviour of Al foundry alloys Knowledge about casting defects (limiting the mechanical behaviour of cast products) Design rules and guidelines to combine microstructure, defects and mechanical behaviour of cast products Increased robustness in mechanical design Reliable data on mechanical behaviour of Al foundry alloys produced Increased possibility of supporting foundries in alloys selection Knowledge about casting defects and on the actions to be performed to increase cast products quality Increased possibility of interacting with customers in a concurrent engineering approach (supported by standards and guidelines) possibility of employing components produced with a more knowledge-based approach, thus improving the technological margin of their products (improved reliability and safety, cost optimisation, reduced time-to market) 35 Project Scenario attuale per la Qualità 36 18

19 Project Scenario futuro per la Qualità 37 Project Website

20 New Quality and Design Standards for Aluminium Alloys Cast Products

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