Jürgen Wüst October 2008

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2 Innovative High Integrity Die-casting High-Q-Cast

3 Why Invest in Aluminum Die-casting techniques Use of aluminum automobile components continues to grow steadily: average of 54 lb (25 kg) per car lb (124 kg) lb (144 kg) (projected) To reduce weight and improve fuel economy Political, social, and consumer pressures - auto manufacturers are listening.

4 Aluminum Opportunities New applications like heat-treatable structural aluminum parts will see the largest growth as entire new markets are created. Those parts are higher margin, and offer a clear competitive distinction for die-casters. Already driving growth for European die-casters.

5 Key Figures BDW technologies GmbH Employees 323 Turnover 50 Mio. Euro in 2007 Production to / anno - 5 Mio. parts / anno - Ca. 100 different products in Aluminium Vacuum High-Pressure Die-casting

6 Know-how in High-Integrity Die Castings Alloy AURAL-2 and heat treatment AURALTHERM 1997 AUDI A2 24 parts, first supplier in high volume series production 2004 AUDI A8 Takeover of 8 parts from a competitor (+GF+) 2003 BMW X5 Development project Changing to Aural-2 by BMW 2004 Jaguar XK Development and series production of 12 parts 2004 Proton MSX Development project with mit LOTUS 12 parts 2004 AUDI TT Development and series production of 4 parts 2005 GM Safe Development project with GM and Contech, USA 2007 Daimler Current development partner for several projects Magna Steyr Porsche Audi

7 Typical Die Casting Defects Shot from scanning electron microscope (SEM) Trapped gases - (high magnification)

8 Typical Die Casting Defects Shot from scanning electron microscope (SEM) Areas indicating a material separation (Oxide)

9 Typical Die Casting Defects Areas containing shrinkage porosity Magnification: 150 x

10 Factors affecting die-casting quality Alloy composition and impurity Metal quality (oxides, hydrogen content, sludge, dross, other inclusions) Metal temperature, treatment, transfer, delivery to shot sleeve Die-casting machine (size, type, equipment) - Clamp/platen: clamp pressure/platen programmable - Shot end: shot speeds/profile, pressure, closed loop control Monitoring system: - for all critical process parameters - full machine diagnostics - graphical user interface (HMI) provide SPC Shot tooling: - Cold chamber (proper size, internal temperature control, etc.) - Shot tip (with ring to create seal and internal cooling), - Plunger lube (type and application) Die-casting dies / gating design / overflow design Part design (wall thickness, changes, etc.) Die temperature Lubricant type, application and efficiency Vacuum system: level & type / cavity pressure / control Part extraction and quench system Trimming Heat treatment and other process steps

11 Gas Porosity inside a Welding Seam

12 Gas Porosity inside Die Castings Standard Die-casting Standard Vacuum Die-casting High-Q-Cast 0% 0 % 0,16% 0.16 % 0,4% 0.4 % 1,00% 1 % 2.5 2,5% % Density Index DI

13 Complete Die Casting Process Technology

14 High integrity high vacuum HPDC Typical Process Chain for H-I-Castings including Q- Gates Melting Degassing Casting & Trimming Heat Treatment Q-Gate Q-Gate Q-Gate Q-Gate Compositio n Density Check X-Ray Weldability Crack Inspection Blister Check Tensile Test Straightening Castings ready to assemble Washing, Etching & Convers.- coating Dispatch Machining Q-Gate Visual Check Q-Gate Dimension al Check Q-Gate Size Check Martin Hartlieb Vacuum

15 Aural Alloys: Special alloys have been developed to meet mechanical properties of new applications

16 Numerical Simulation for Die Fill and Solidification Part Design Process- Parameter Simulation Software Material Data Defect Prediction Incomplete Die Fill Soldering Trapped Gases Shrinkage Porosity Optimization Gate Desin Part Design Process Conditions Distortion Thermical Stresses

17 Key to Success: Numerical simulation Runner design optimization - provide a continuous flow path into and through the part Overflow optimization (including vacuum valve position) Utilization of gates along nearly entire front edge of part Casting defects prediction Temperature distribution at surface of the cavity Velocity field in the liquid metal during die filling

18 Process Analysis Solidification (Shrinkage Porosity)

19 Process Control Die Temperature

20 Process Analysis Die Fill (Gas Porosity)

21 Key to Success: Product Development Component Design - Robust designs meet both functional & manufacturing requirements - Robust component designs lead to higher quality products - Design engineers should collaborate with casting engineers in the early stages of product development Gating and Die Design - Simulation is a must - Gating design is important - Vacuum gating is also important and often overlooked

22 Gate Calculation

23 Melt Treatment Periodic Chemistry Check De-gassing

24 Sure-Trak2 Shot Control System Produce Precise and Repeatable Injection Control

25 Key to Success: Lubricant Selection Minimize evolution of gas (and subsequent entrapment in castings) resulting from reaction between lubricants and molten metal Shot tip with ring to seal cold chamber Various Gases Generated from Different Lubricants

26 High-Q-Cast Control Unit - Main Screen

27 High-Q-Cast Control Unit - Limit Set Point Screen 0.5 PSI

28 Components Vacuum Line

29 Components Coarse / Dust Filter

30 Components Solenoid Valve

31 Components Hydraulic Control Unit

32 Components Vacuum Valve Activator

33 Components Vacuum Die Valve

34 BDW has selected some die release chemistry that is effective in minimizing contamination of the casting

35 Humidity Monitoring Computer Controlled Casting Software

36 High integrity high vacuum HPDC Vacuum and moisture are not compatible! Martin Hartlieb Vacuum

37 Aural-2 AlSi10MgMnFe

38 Alloy AURAL-2 (AlSi10MgMnFe) Auraltherm Chemical Analysis (wt. %) Si: 10 % Mg: 0.3 % Mn: 0.5 % Fe: 0.18 % Ti + Sr grey: quaternary AlFeMnSi phase Which properties are related to the single alloying elements? Si: castability, (mould filling, solidification shrinkage, etc.) Mg (+ Si): strength Mn + Fe: avoid sticking to the die Fe: crack initiation, corrosion behaviour

39 Property Potential of AURAL-2

40 Alloys for high vacuum high integrity HPDC Examples: Chemical composition of Aural alloys Aural-4 A-Alloy

41 Alloys for high vacuum high integrity HPDC R m [ Mpa ] RP 0,2 [ Mpa ] A 5 [ % ] Condition F Aural T Auraltherm F Aural T Auraltherm F Aural T T6 A-Alloy F T5 SSF Properties Example mechanical Properties of Aural alloys

42 Alloys for high vacuum high integrity HPDC Mechanical properties as cast + 40 minutes artificial aging at 210C Mechanical Properties of Aural-5S in T5 temper

43 Compression test with Aural-2 cast structures No cracks in the deformation zones!

44 Compression test with Aural-2 cast structures

45 AUDI A2: Three High-Q-Cast Castings: Heat treated & MIG welded together form this component from the front area A-pillar Strut dome Upper and lower longitudinal member

46 Example: High Integrity Die Castings (Audi TT) Requirements: Yield > 120 MPa Tensile > 180 Mpa Elongation > 15 % True to size Weldability Corrosion Resistance A-Pillar outer right A-Pillar inner right Source: Audi AG Alloy: GD-AlSi10MnMg (AURAL-2 ) Heat Treatment: AURALTHERM A-Pillar inner left A-Pillar outer left

47 Mercedes AMG SLS Utilizes 20 New die-castings in its all aluminum chassis with High-Q-Cast and Sure-Trak2 technology

48 Development and Technology Transfer: Shocktower BMW X5 AURAL-2 Audi AURALTHERM A2 Yield > 120 MPa Tensile > 180 Mpa Elongation > 15 % Product development: Shock Tower Prototypes Pilot-series casted at BDW technologies. Technology transfer for serial production and support to CONTECH, Clarksville, TN.

49 Continuous Heat Treatment Line Auraltherm 1 st Floor Heat Treatment Racks Loading Area Lift Inspection / Unloading Area max. number of Racks: 120 Processing Time: 140 min. Cooling Lift Aging 2 nd Floor Air Quenching Solution Treatment

50 Temp. [ C] 860 F hold on solution temp. 460 C ±5K / > 60 min Temp Ref. Lines. Solution treat Process with tolerance cooling rate 430 F hold in annealing furnace 223 C including heating-up ±5K / min. time

51 Porsche suspension parts in Aural-alloy 6 4 PORSCHE REAR AXE Cross member (1) 5 3 Longitudinal beam (2) Control arm (3) 1 2 Strut dome (4) Rear axe cross member (5) Side beam (6)

52 Aural-5 : (AlSi7MgMnFe) [%] : Chemical Composition Si Mn Fe Mg Ti Sr 6,8 7,2 0,5 0,6 0,18 0,2 0,34 0,38 0,04 0, ppm % Eutectic ca. 60 % Eutectic Liquid Temperature, F α 1.65% S + α (Al) 577 C α + Eutectic (α + β) Aural-5 S + β (Si) 11.7% β + Eutectic (α + β) Al (100%) Silicon-Weight- %

53 Traceability

54 Ductile Oilpan Requirements (without Heat Treatment) Flange Hardness : 70 HB Elongation (Bottom) : 8 % Stone-Chipping Resistance : 65 pound force - foot Leak Tightness : 5 ml / min

55 Ductile Oilpan Stone - Chipping Resistance : 88J Steel Ball : 4.5 lb / Ø 3.15 in Height of Fall : 13.8 ft Energy : 88J (65 pound force-foot) W = 88Joule L = 13.8 ft

56 Ductile Oilpan Results (Alloy 380) Leak Tightness : 2 ml / min Flange Hardness : 95 HB Elongation (Bottom) : 2 % Stone Chipping Resist.: 35 lb force-ft Alloy 380

57 Ductile Oilpan Results (Alloy: Aural-5 ) Leak Tightness : 2 ml / min Flange Hardness : 88 HB Elongation (Bottom) : 10 % Stone Chipping Resist.: 96 lb force-ft Aural-5 As Cast

58 License Package Per Die-casting Machine - Vacuum Technology - CCC-Monitoring - Humidity Monitoring - Metal Treatment Specifications - Cold Chamber Metering Device - Die Lube / Tip Lub Release Agent and Application - Production Start-up Support - Additional Support on Demand

59 License Package (cont.) Die-casting Alloy AURAL - Guidelines (Melting, Casting) - Chemical Composition (Specification) - Melt Treatment Heat Treatment AURALTHERM - Guidelines (Temperatures, Times) - Air Quenching (Reduced Distortion) Engineering Support - DCM-Set-up, HT-Process, Melting, - Project Management (BDW Licensee - OEM / Tier I)

60 Jack Vann CEO Visi-Trak Worldwide 8400 Sweet Valley Drive, Suite 406 Valley View, OH USA Office Phone: x24 Martin Hartlieb Viami International, Inc. 267 Rue Alice Carriere Beaconsfield, QC, H9W 6E6 Canada Office Phone: