Technology Roadmap for Energy Reduction in Automotive

Applications
•Cylinder heads
•Torque converter
housings
•Cylinder blocks
•Intake manifolds
•Transmission cases
•Electric motor
housings (hybrid vehicle)
•Electric rotors (hybrid
vehicle)
•Chassis components
Exhibit 6.5 Priority Topic Powertrain
Energy Efficient Casting Technologies
Innovative process and material technologies to significantly improve the energy efficiency (increase
casting yield, scrap reduction, lower heat treatment energy) of die‐cast die‐ cast and semi‐permanent semi‐ permanent mold
(SPM) casting processes. Novel sand‐cast sand‐ cast process technology (less heat treat energy, higher
mechanical properties) for cylinder head high‐volume high‐ volume applications
Partners
I –Productiondemonstration,
–Production demonstration,
data collection
F/G – Sensor/instrumentation
development, data collection,
pilot‐scale facility
U –Data collection, pilot‐scale
facility
• Lack of casting research funding
• Lack of casting research facilities
• Lack of sensors and instrumentation
to measure process parameters
• Lack of validated computational
analysis tools
R&D Timeline
Near ‐ Develop pilot pilot‐scale ‐ scale facilities, capabilities, and
methods; met hods; instrumentation for die die‐casting, ‐ casting, se semi‐ mi‐
permanent mold and novel sand sand‐cast ‐ cast proces processes ses
‐ ‐ Integrate casting process parameters (mea (measured) sured)
into com computational putational analysis tools (temperatu (temperature, re,
pre pressure, ssure,
fill pattern)
Mid ‐ Optimize analysis tools using experimental
validation data
‐ Develop production‐ready instrumentation
(conta (contact ct and non non‐contact) ‐ contact) for monitoring pr process ocess
parameters parameters (die (die‐cast, ‐ cast, SPM, novel, sand sand‐cast ‐ cast
process)
Long ‐ Production demonstration of die die‐cast ‐ cast and SPM
innovative process technologies (cylinder he heads, ads,
SPM transmission case –diecast) –die‐cast) ‐
‐ Validated analysis tools to accurately predic predict t
prese presence nce of porosity (micro, macro), oxides,
mmicrostructure,
icrostructure, residual stress, mechanical
pproperties
roperties (ultimate tensile strength [UTS],
ffatigue)
atigue)
Technical
Commercial
Other
Challenges
Risks
8.31.09
Targets
• Reduce casting scrap by
50%, reduce energy
needed to process
components
•Improvedcasting •Improved casting yield by
50%
•Castingalloys •Casting alloys that
achieve/exceed
permanent mold
properties, require
minimal heat treatment
• Validated novel sand‐
casting process for cylinder
head components, where
mechanical properties
exceed permanent mold
Benefits
Energy
•Reducedscrap, •Reduced scrap, higher
casting yields, less intensive
heat treatment
Environment
•Reducedemissions
•Reduced emissions
Economics
• Significant cost benefits due
to reduced scrap, reduced
heat treatment, higher casting
yields
TECHNOLOGY ROADMAP FOR AUTOMOTIVE MANUFACTURING ENERGY REDUCTION 33