SECTION ADDRESSED TO FOUNDRIES

Transcription

1 SECTION ADDRESSED TO FOUNDRIES NOTE: 1) All the information implemented will be anonymously processed in view of the targets of StaCast Project. 2) The results of statistics elaboration from data will be made available to all persons which answered the questionnaire. 3) The questionnaire SHOULD BE FILLED ONLY by the foundries that apply High Pressure Die Casting and/or Low Pressure Die Casting and/or Gravity Die Casting processes. 1 - Company Information and Profile 1.1) Company name * : (Write your Company name) 1.2) Contact name * : (Write Your name) 1.3) * : (Write a valid address) 1.4) Phone number: 1.5) Field (Please do not change this value) 1.6) Type of company * : SME IND SME: <250 employees; turnover < 50 million Euro/year IND: > 250 employees; turnover > 50 million Euro/year 2 - General Data on Production 2.1) Annual production (ton/year) * < to to to > ) Which is the main production process in your foundry? * HPDC Gravity / Low pressure 2.3) Alloys used * EN-AC [Al-Si7-Mg0,3] EN-AC [Al-Si7-Mg0,6] EN-AC [Al-Si10-Mg(Cu)] EN-AC [Al-Si10-Mg(Fe)] EN-AC [Al-Si12(Fe)] EN-AC [Al-Si9] EN-AC [Al-Si9-Cu3(Fe)] EN-AC [Al-Si11-Cu2(Fe)] 1

2 EN-AC [Al-Si8-Cu3] EN-AC [Al-Si9-Cu3(Fe)(Zn)] EN-AC [Al-Si12-Cu1(Fe)] EN-AC [Al-Mg9] EN-AB [Al-Si11] EN-AB [Al-Si12] EN-AB [Al-Si7-Cu3-Mg] EN-AB [Al-Si12-Cu-Ni-Mg] EN-AB [Al-Zn10-Si8-Mg] Other (specify) 2.4) Other Alloys: 2.5) Application * : (Max 2 choices) Automotive Mechanical Engineering Electronics Architecture and Design Other 2.6) Primary and secondary categories of Castings Primary category of Castings: Thin walls components Safety components Housings, covers Engine blocks Other (specify) Primary category of Castings - Specify OTHER * : Secondary category of Castings: Thin walls components Safety components Housings, covers Engine blocks Other 2

3 3- CEN Standards European Standards (CEN) adopted and used in your company *: EN Founding - Technical conditions of delivery - Part 1: General EN Founding - Technical conditions of delivery - Part 4: Additional requirements for aluminium alloy castings EN 1676 Al and Al alloys - Alloyed aluminium ingots for remelting - Specifications EN 1706 Aluminium and aluminium alloys - Castings - Chemical composition and mechanical properties EN Aluminium and aluminium alloys - Part 1: Numerical designation system EN Aluminium and aluminium alloys - Part 2: Chemical symbol based designation system EN Aluminium and aluminium alloys - Part 3: Writing rules for chemical composition EN Aluminium and aluminium alloys - Terms and definitions - Part 1: General terms EN Aluminium and aluminium alloys - Terms and definitions - Part 2: Chemical analysis EN Founding - Radiographic examination EN Aluminium and aluminium alloys - Chemical analysis - Sampling from metal melts None Info on Aluminium Alloys European Standards (pdf document) 4- Need for new European Standards Please specify your interest for having new European Standards in the field of Aluminium alloys cast products New CEN Standard about Classification of casting defects * Very high High Medium Low Any 3

4 New CEN Standard about mechanical properties of Al-based casting alloys * Very high High Medium Low Any New CEN Standard about mechanical properties of Al-based castings * Very high High Medium Low Any New CEN Standard and-or Guidelines on Al-based cast products design * Very high High Medium Low Any 5 - Defects Analysis For each type of defect, tick the applied methods of control specifying if they are carried out on 100% of castings or on a statistical basis Main castings category (Please do not change this value) 5.1) Analyzing Defect - Gas/Air Porosity (air, hydrogen, vapour, lubricant entrapment,...) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 4

5 Is this type of defect measured and/or quantified? Yes No 5.2) Analyzing Defect Inclusions (oxide skins, refractory,...) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Is this type of defect measured and/or quantified? Yes No 5.3) Analyzing Defect - Shrinkage (macro-shrinkage, micro-shrinkage/interdendritic shrinkage) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 5

6 100% Production Statistical basis Not used Not applicable Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Is this type of defect measured and/or quantified? Yes No 5.4) Analyzing Defect - Cracks (hot tears, cold cracks) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Is this type of defect measured and/or quantified? Yes No 6

7 5.5) Analyzing Defect - Filling-related defects (cold joint, lamination, cold shot) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Is this type of defect measured and/or quantified? Yes No 5.6) Analyzing Defect - Metal-die interaction (soldering, ejection mark, thermal fatigue...) *, CT scan 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable 7

8 Ultrasonic testing 100% Production Statistical basis Not used Not applicable 100% Production Statistical basis Not used Not applicable Is this type of defect measured and/or quantified? Yes No 6 - Please indicate how often these defects categories are present in your production Gas/Air Porosity * (air, hydrogen, vapour, lubricant entrapment) Inclusions * (oxide skins, refractory) Shrinkage * (macro-shrinkage, microshrinkage/interdendritic shrinkage) Cracks * (hot tears, cold cracks) Never Occasionally Frequently Very frequently Never Occasionally Frequently Very frequently Never Occasionally Frequently Very frequently Never Occasionally Frequently Very frequently Filling-related defects * (cold joint, lamination, cold shot) Metal-die interaction * (soldering, ejection mark, thermal fatigue,...) Never Occasionally Frequently Very frequently Never Occasionally Frequently Very frequently * : Required field 8