ALUMINIUM TECHNOLOGY HIGH-PERFORMANCE ALUMINUM TECHNOLOGY
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1 ALUMINIUM TECHNOLOGY HIGH-PERFORMANCE ALUMINUM TECHNOLOGY Lightweight Aluminum in Powder Metallurgy
2 THE MARKET S DRIVE TOWARD LIGHTWEIGHT TECHNOLOGY TECHNOLOGY Market Drivers CO 2 emissions and fuel economy standards are mandating vehicle mass reduction 220 Passenger car CO 2 emissions and fuel consumption, normalized to NEDC Internal combustion engines and hybrid electric vehicle efficiency hinges on smaller engine size, increased transmission speed Reduction in mass reduces energy use for all forms of energy: ICE, Hybrid, and Electric GKN Solutions GKN s lightweight technology minimizes component mass without compromising performance GKN s advanced Powder Metallurgy (PM) technology produces high-strength, net-shape parts geared toward ICE, hybrid and vehicle electrification Grams CO 2 per kilometer, normalized to NEDC Mexico 2016: 145 Japan 2020: 122 historical performance enacted targets Brazil 2017: 138 S. Korea 2020: 97 EU 2021: 95 KSA 2020: 142 India 2022: 113 China 2020: 117 US 2025: 97 Canada 2025: Liters per 100 kilometers (gasoline equivalent) GKN is the leader in PM technology and develops lightweight, high-performance Aluminum materials and products Year Graph/The International Council in Clean Transportation
3 COMBINING EFFICIENT PROCESSING WITH ADVANCED LIGHTWEIGHT MATERIALS GKN ALUMINUM MMC Why Powder Metallurgy? Why GKN? Unrivaled Design Freedom Unique part geometries Simplified product design without compromised functionality High material utilization greater than 90 percent Rapid prototype development, scalable to highvolume production Aluminum Metal Matrix Composite (Al MMC) Technology Hard ceramic, uniformly distributed within tough Al-alloy matrix Improved static and dynamic performance over conventional Al-alloys Readily forgeable, significantly increasing mechanical performance Novel Al-Alloy with High Thermal Conductivity (TC2000 series) Versatile material for thermal management applications TM PRODUCT Heat Management Transmissions Hydraulic Engines Net shape Efficiency Inertia Thermal Mass
![MATERIALS GKN s GKN S ALUMINUM MMC MMC Specific Strength Wear Resistance 6.587 Specific Strength Tensile [(MPa)/(g/cm3)] ASTM G77 Block-on-Ring Wear Test Increasing Wear Resistance 3.](/docs-images/84/89284676/images/4-0.jpg "387 222 232 Wear Scar Width (mm) 1.954 1.467 167 0.")
4 MATERIALS GKN s GKN S ALUMINUM MMC MMC Specific Strength Wear Resistance Specific Strength Tensile [(MPa)/(g/cm3)] ASTM G77 Block-on-Ring Wear Test Increasing Wear Resistance Wear Scar Width (mm) Al T6511 Cast AI A380 Cast AI B390 Al PM MMC Cast Iron Materials Steel Forgings Steel PM Distaloys Titanium Forgings Aerospace Al MMCs GKN's Al Forged MMC GKN's Al PM MMC Al Castings Mass Change of Ring (g) Higher strength-to-weight Forging specific strength Superior resistance Minimized oil conta- CTE match with ratio, allowing for mass exceeds steel PM alloys to sliding wear for mination (no abrasive aluminum housing reduction and improved and forgings use in hydraulic Si particles), improved improves overall vehicle efficiency applications pump efficiency pump efficiency
5 MATERIALS GKN S ALUMINUM TC2000 SERIES TC2000 Thermal Conductivity Thermal Conductivity (W/m-K) GKN s TC2000 is the PM counterpart to commercially pure, wrought aluminum. Cast AI A TC2000 outperforms conventional extrusions and castings by limiting AI solute impurities within the alu- AI minum matrix. Al PM TC Pure Aluminum 234 Qualitative Benefits Formability Manufacturability Green Design Unique, net-shape geometries with excellent tolerance control without costly machining High production volumes with reliable performance Minimal material scrap and completely recyclable material, minimizing environmental impact GKN engineers use modeling and simulation to ensure optimized designs, meeting customer requirements
6 LIGHTWEIGHT UR APPLICATIONS SOLUTIONS Camshaft Bearing Caps GKN Powder Metallurgy produces over 30 million engine camshaft caps per year, designed to exceed unique customer requirements. Several material options allow for design flexibility to optimize geometric precision, strength, toughness, wear resistance and/or cost. GKN s PM netshape design only requires customer line bore High wear and fatigue resistance (with optional MMC material) Unique Z-loc, for dowel elimination
7 LIGHTWEIGHT UR APPLICATIONS SOLUTIONS Planetary Reaction Carrier This MPIF award-winning Planetary Reaction Carrier is the first commercial use of powder metal Aluminum MMC material for a carrier application. The technology won the 2018 Grand Prize in the MPIF Design Excellence Awards. Introduction of aluminum reduced the mass of the carrier application by 1 kg High wear resistance and lower inertial mass Maintains strength and fatigue at operating temperature of 150 degrees Celsius Industry-winning dimensional precision
8 LIGHTWEIGHT UR APPLICATIONS SOLUTIONS Forged Products GKN is in production development Bending Fatigue Strength of Aluminum forged products: 400 Tailored preform design allows Bending Stress (+/- MPa) GKN s 2618 MMC Wrought 2618 for highly controllable plastic flow Near-net shape, and economical process eliminates subsequent working operations Fatigue properties exceed wrought forged Aluminum ,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08 Conventional Forged Material GKN s Forged MMC Material
9 LIGHTWEIGHT UR APPLICATIONS SOLUTIONS Heat Sink GKN s heat sink was developed to replace die cast components for a car radio cooling application. Unique tower and three section sizes, not practical for casting or extrusion Higher thermal conductivity, requiring less thermal mass No machining required, providing cost savings High ductility, reducing risk of cracking during mechanical attachment
10 UR SOLUTIONS Contact us here ALUMINUM TECHNOLOGY Alan Taylor Lightweight Technology GKN Powder Metallurgy 2018
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