EXPERIENCE OF ALFA GROUP IN
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1 EXPERIENCE OF ALFA GROUP IN MANUNET PROJECTS MANUNET Annual Conference Florence, Italy 23 April 2009 Dr. Pedro Pablo Rodríguez
2 OUTLINE 1. BRIEF PRESENTATION OF ALFA GROUP 2. PARTICIPATION OF ALFA UNITS IN MANUNET PROJECTS 2007: INVAUT 2008: COMP-μ-INJECTION, LASCLEAN 2009: QUAMINET 3. GENERAL CONSIDERATIONS OF MANUNET PROJECTS 4. SUMMARY AND CONCLUSIONS
3 1. BRIEF PRESENTATION OF ALFA GROUP
4 HISTORY the 20 s industry Firearms, sawing machines Industrial Applications, artworks, home appliances
5 STRUCTURE 14 small-medium sized companies Tool manufacturing R&D unit Cold forging Precision machining Investment casting, MIM Commercialization Casting Automotive Automotive, elevators Automotive, aeronautics Domestic appliances Sculptures, artwork
6 INTERNATIONAL ACTIVITY Basque Country (Headquaters) Romania China Production plants Representative offices
7 2. PARTICIPATION OF ALFA UNITS IN MANUNET PROJECTS
8 CALL 2007: INVAUT Title: High Performance Magnesium Investment Casting for Automotive Applications Duration: 3 years ( ) 2010) Budget: Basque Country North-Rhein Westfalia Investment t casting foundry Casting simulation Process development Magnesium casting Magnesium cast housings for automotive industry, substituting aluminium and/or plastic End-user
9 TECHNOLOGY: INVESTMENT CASTING Wax injection Wax tree mounting Ceramic coating Final part Pouring Dewaxing
10 TECHNOLOGICAL CHALLENGES Advantages of magnesium: Similar mechanical and thermal behaviour compared with aluminium alloys 30% weight reduction when substituting aluminium by magnesium Disadvantages High reactivity of molten magnesium with oxygen and ceramic mould Oxides, mould burning Unknown rheological behaviour of the molten magnesium inside the ceramic mould Technological challenge: Develop a specific investment casting process for magnesium alloys oxides
11 MARKET CHALLENGES TARGET MARKET: Transport industry 30% lighter products with advanced mechanical properties reduction on fuel consumption Weight reduction improves vehicle performance by enhancing acceleration/deceleration. Magnesium parts can be tuned to critical frequencies where noise, vibration and harshness are reduced Lighter structures can be removed ed and/or reconfigured ed to allow ao easier e egress ess and ingress; gess; e.g. a 3rd-row magnesium seat is 18 Kg. lighter than a heavier steel fabrication. Magnesium castings can have reduced manufacturing cost vs. steel, especially for production volumes of less than units/year. For example, a 30-part steel cross-car beam requires 30 expensive tools/gauges; the cast-magnesium version has only 6. A one-piece cast-magnesium cross-car beam can reduce dimensional error vs. stamped/welded steel elements. Magnesium has higherh strength, th stiffness, thermal stability and thermal conductivity it vs. plastic; higher specific strength, ductility and impact resistance vs. aluminum as well as better damping and dent resistance vs. steel
12 WORKFLOW Process design and modelling Process monitoring Experimental tests Microstructural and mechanical characterization
13 RESULTS Reduce mold-metal reactions Development of an alumina-based coating Development of inhibitors (NaBF 4,SF 6,...) Definition of casting conditions for magnesium alloys using a simulation/experimental approach Development of specific crucible for magnesium melting Optimization of process parameters (melt and mould temperatures, pouring velocity, mould transfer time,...) Calculation of solidification curves via thermocouples embedded in the mould Supported by process simulation Characteristics validated by end-user
14 SCIENTIFIC PRODUCTION 1 Master Thesis 1PhD A. Gorosarri. Modelización y desarrollo del proceso de microfusión de magnesio para la elaboración de componentes aeronáuticos, Mondragon Unibertsitatea, July 2008 G. Arruebarrena. Relationship between Solidification, Microstructures and Mechanical Properties of Magnesium Cast Alloys, Mondragon Unibertsitatea, March presentations in scientific conferences Spanish National Conference on Materials Science, San Sebastián (Spain), June 2008 N. Herrero Dorca, A. Gorosarri, G. Arruebarrena, P. P. Rodríguez, M. Oiarbide, I. Hurtado. Simulación y experimentación del proceso de microfusión para la aleación de magnesio AZ91E G. Arruebarrena, I. Hurtado, H. Sarriegi, K. Weiss. "Análisis de microestructuras y propiedades mecánicas en aleaciones de Mg coladas en coquilla por gravedad International Conference on Magnesium Alloys and Applications, Weimar (Germany), October 2009 N.Herrero-Dorca, G. Arruebarrena, H. Sarriegi, U. Beristain, U. Andres, Y. Bilbao, P. P. Rodriguez, K. Weiss, I. Hurtado. Investment Casting of a AZ91E Thin-Walled Complex Component. G. Arruebarrena, N. Herrero, H. Sarriegi, K. López, P. P. Rodríguez, I. Hurtado. Thermal conductivity of high-pressure die-cast AM50 and AZ91D alloys 1 patent under preparation
15 CALL 2008: LASCLEAN Title: Laser cleaning, polishing and multi spectral analysis of surfaces for artworks, artwork restoration and industrial applications Duration: 3 years ( ) Budget: Basque Country Piedmont Fonderia Artistica di Piero de Carli e C. s.a.s.
16 CALL 2008: COMP-μ-INJECTION Title: Tools and methods for competitive μ-injection process industrialization Duration: 2 years ( ) Budget: Basque Country Piedmont Slovenia
17 CALL 2009: QUAMINET Title: Adaptive quality control for the μ-injection moulding technology via neural networks Duration: 2 years ( ) Budget: Basque Country Germany
18 3. GENERAL CONSIDERATIONS OF MANUNET PROJECTS
19 POSITIVE ASPECTS International project Small consortium easier management Local funding well-known administrative process Many regions involved it is possible to find good partners Very useful tool as a first experience in international projects for small companies Two-stage process No waste of time if project is not suitable Efficient support by local agencies
20 NOT SO POSITIVE ASPECTS Extremely long administrative process, e. g. INVAUT project: Idea December 2006 Manunet 1st stage June 2007 (approval: 11 July 2007) Manunet 2nd stage October 2007 (approval: 3 December 2007) Project start date 1 January 2008 Basque local programme (2008) June 2008 (approval: February 2009) 70% of approved funding March 2009 Remaining 30% of approved funding 2010 (hopefully,...) Basque local programme (2009) June 2009 etc...
21 4. SUMMARY AND CONCLUSIONS
22 CONCLUSIONS ALFA experience in MANUNET projects is very satisfactory: 3 approved projects in 2007 and 2008 (out of 3 presented) 1 project presented to MANUNET 1st stage in 2009 More to come MANUNET projects allow transnational cooperation avoiding difficulties linked to conventional large-scale European projects MANUNET is a extremely convenient tool as a first experience in European projects for small-medium sized companies Everything seems wonderful, but: Be patient with administrative process!!!
23 THANK YOU FOR YOUR ATTENTION ALFA GROUP Torrekua Eibar (Spain) Phone: Fax: prodriguez@alfalan.es
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