AIT Austrian Institute of Technology Department Mobility Business Unit Light Metal Technologies Ranshofen LKR Leichtmetallkompetenzzentrum Ranshofen

Transcription

1 AIT Austrian Institute of Technology Department Mobility Business Unit Light Metal Technologies Ranshofen LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

2 Light Weight Structures and Light Metals for New Electric Vehicles Dipl.-Ing. Rudolf Gradinger Head of Business Development LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Conference on Alternative Propulsion Systems and Energy Carriers, October 16th 2009, TechGate Vienna Dipl.-Ing. Rudolf Gradinger Head of Business Development Light Metal Technologies Ranshofen Department Mobility AIT

3 Outline General Information about LKR Main activities regarding Light Weight Structures and Light Metals for New Electric Vehicles Outlook Conclusion

4 General Information about LKR Development, integration in AIT organisation, LKR organisation chart

5 General Company Information Austrian Institute of Technology (AIT) Number of employees: 977 LKR Location: Seibersdorf, Austria Blin dtext auf einer PPT-Folie, ein Text without weitere Bedeutung, allein Ranshofen Vienna Largest non-university research establishment in Austria der Visualisierung LKR eines grafischen Konzeptesdienend. (16pt) Number of employees: 37 Location: Ranshofen, Austria Turnover: about 5 million euros 100% subsidiary of the AIT Non-university research establishment Certificates ISO 9001 ISO Seibersdorf AIT Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung, allein der Visualisierung dienend.

6 AIT Austrian Institute of Technology

7 LKR s main focuses AIT is one of Europe s leading mobility research centres. LKR a business unit of AIT s mobility department and focuses on: Material development Process development Material based design

8 Light Weight Structures and Light Metals for New Electric Vehicles

9 Main targets and research topics Optimal utilisation of the properties of light alloys in single parts, components and assemblies, especially as a combination of low weight and high safety characteristics Material based design of highly complex parts Knowledge & simulation based process optimization before prototyping Knowledge & simulation based material development Energy storage (e.g. LH2) Structure (e.g. space frame for the Steyrer 1050 car) Drives (e.g. in-wheel motor) 13/10/2009 9

10 Light weight, light alloy space frame Structural design (with focus on static stresses, crash deformation, energy absorption) of (hybrid) space frame technology using sheets, cast nods, extrusions of Aluminium & Magnesium alloys Design and optimization of loads transfer in structural joints (metal + metal; metal + fibre reinforced polymers. riveting; adhesive bonding; IGEL technology, ) (Hybrid) shape casting of space frame joints Utilisation of materials concerning special properties e.g. local energy absorption by folding

11 Energy absorption LKR has a long history in design and optimization of crash energy absorbers (incl. bullet proof materials), starting from Aluminium & Magnesium foam technologies over foam filled steel profiles, heat treatment studies of conventional alloys with higher energy absorption to simulation based deformation design of space frames or purpose built crash absorbers S355J2G3 (1.0570) Dichte: 5,4 g/cm³ 6,7 Auflageflächen/cm² Druckspannung [MPa] 80 S355J2G3 (1.0570) Dichte: 2 g/cm³ 70 1,3 Auflageflächen/cm² AA6082-T6 Dichte: 0,96 g/cm³ 6,7 Auflageflächen/cm² AA6082-T6 Dichte: 0,7 g/cm³ 1,3 Auflageflächen/cm² AA1085 Dichte: 0,81 g/cm³ 1,6 Auflageflächen/cm² Stauchung [%]

12 Hollow extrusions as energy absorbers Conventional high strength Al alloys usually show different grain sizes and precipitations (resulting in different mechanical properties) due to insufficient cooling rates along the thickness of the walls. The coupling of FEM (Procast, LS-DYNA) & analytical tools (based on MatCalc) for the optimization of energy absorber properties on microscopically and macroscopically levels will offer a method for the best utilization of properties of profiles manufactured by industrial processes.

13 Virtual crash performance studies of design iterations for the crash energy absorption of heavy battery packs t = 25 ms t = 25 ms t = 75 ms t = 75 ms

14 Energy storage & containers LKR was / is / will be cooperating with different companies/consortia concerning design, prototyping & evaluation of a non-cylindrical liquid hydrogen tank a cylindrical gaseous hydrogen pressure tank a non-cylindrical solid-state hydrogen container

15 Electric drives & range extenders LKR will be cooperating with different companies/consortia concerning design, prototyping & evaluation of components of in-wheel drives range extender engines

16 Additional topics LKR is currently studying Light alloys for usage in batteries as an anode (Magnesium-Air-concept) Contamination of light alloy scrap by Lithium from batteries (causing e.g. Brittleness in Aluminium products)

17 Outlook & Conclusion

18 Outlook & Conclusion The LKR Leichtmetallkompetenzzentrum Ranshofen GmbH forms the Business Unit Light Metal Technologies Ranshofen of AIT s Mobility Department. LKR is advancing its long lasting expertise in order to meet the challenges of new electric vehicles. LKR is cooperating with many different Austrian companies on topics like light weight structures, energy storage or drives. LKR contributes to AIT s efforts to develop appropriate solutions for the environmentally compatible, efficient and safe mobility of the future!