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Casting Technology

Our research focuses on both innovative process technology and material development.

Mitarbeiterfoto Peter Randelzhofer

P. Randelzhofer, M.Sc.

Mitarbeiterfoto Tobias Gaag

Tobias Gaag, M.Sc.

Mitarbeiterfoto Paul Git

Paul Git, Dipl.-Phys.

Mitarbeiterfoto David Himmler

David Himmler, M.Sc.

Mitarbeiterfoto Benjamin Wahlmann

Benjamin Wahlmann, M.Sc.

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Project B1 focuses on the investigation of the newly developed FCBC (Fluidized Carbon Bed Cooling) process for the single crystalline solidification of superalloys. In comparison with commercially available investment casting processes it could be shown that FCBC benefits from a higher cooling potential. In combination with a dynamic baffle a higher axial temperature gradient will evolve. Objective of the upcoming project period is the improvement of the process understanding as well as the process optimization, carried out on a 10 kg prototype plant. A further point of interest is the exploitation of the increased microstructural homogeneity for alloy development.

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A new numerical tool will be explored that supports the experimental alloy developer in defining new compositions with potential for high strength. Starting with a composition space that is defined by the developer based on his metallurgical experience and his design goals, the numerical tool will propose the most promising compositions. The research program will on the one hand address open questions regarding the mathematical optimization in this application and on the other hand new models for predicting the relevant material properties.

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The scientific service project of SFB/Transregio 103 takes care of the procurement and processing of all project materials.

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The development of Aluminum alloys mainly tends to increase the
strength without worsening the ductility. Beside strength an increase in
stiffness is also sought. In contrast to strength with Aluminium
casting alloys the stiffness can be influenced by alloying to a very
small extent only. A substantial increase in stiffness is possible by
metal matrix composits. But poor wettability between the metal matrix
and the ceramic particels and big differences in the thermal expansion
lead to poor mechanical properties. One possible approach to solve these
problems is using intermetallics based on Aluminium as reinforcement.
These phases have a low density and a good wettability with the
Aluminium matrix. Moreover, these phases can be produced by an in-situ
reaction in the aluminum melt. The volume fraction of the reinforcing
phase increases with this reaction. A special stirring technique ensures
that the reinforcing phase is finely divided.

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With Al-Mg-Si-Mn casting alloys with compositions inside of the pseudobinary section of the subsequent ternary phase diagram, the effect of Zn, Ti, Sc and Ag additions on the precepetation of nanoparticels in as-cast and heat-treated conditions as well as mechanical properties under different conditions (as-cast, solution treated, quenched andaged) will be studied. Despite of the established foundry practce of several Al-Mg-Si-Mn and Al-Zn-Mg casting alloys subjected to high pressure die casting only little research was done either on structure formation or strengthening mechanisms of these alloys and mechanical properties that can be achieved after additional alloying.

In frame of this project as cast conditions of AlMg5Si2Mn alloyed by Zn, Ti, Sc and Ag will be investigated paying attention to precipitates formed in solid solution matrix prior to heat treatment and changes of mechanical properties from as-cast state to age hardened.

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Ziel dieses Teilprojektes ist die Integration piezokeramischer Sensor-Aktor-Module in metallische Bauteile in einem Druckgießprozess. Den Lösungsweg für die schädigungsfreie Integration stellt die Ummantelung der einzugießenden Module mit einer von der Schmelze leicht durchdringbaren Drahtgewebestruktur dar. Hierbei minimiert die homogene Stützwirkung der Gewebestruktur die auf das Modul wirkenden lokalen Kräfte. Mit Hilfe von FE Simulationen wurden Prozessstrategien…

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The aim involved in designing metal matrix composite materials is to combine the desirable properties of metals and ceramics. The addition of high strength, high modulus refractory particles to a ductile metal matrix produces MMCs whose mechanical properties are excellent, such as high strength to weight ratio, high stiffness and good wear resistance. Due to these excellent attributes, MMCs are widely used in aerospace, automobiles, etc.
Among the variety of manufacturing processes available for particle reinforced aluminum materials, stir casting is generally accepted as a particularly promising approach as a result of its simplicity, flexibility, applicability to large quantity production and low costs of production. Though, in preparing particle reinforced aluminum materials by stir casting, we have to consider the following difficulties:
(1) How to achieve a uniform distribution of the reinforcement material.
(2) Promoting the wettability between the two main substances;
(3) Control chemical reactions between the reinforcement material and the matrix alloy.
A new high shear technology can be applied in producing particle reinforced aluminum materials. The aluminum melt is strongly sheared in the semi-liquid or liquid state. The high shear forces produced by a special designed impeller lead to very homogeneous dispersions of additives like particles. In addition, shearing has influence on the homogeneity of the melt and leads to finer grain structures. These effects are expected to be beneficial for the fabrication of metal matrix composites. Therefore, the particular focus of the project is to use shear device to introduce particles into an aluminum melt before die casting and the main aim is to evaluate the potential of the new high shear technology for conditioning of aluminum melts for pressure die casting.

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Die Auslegung von sicherheitsrelevanten Gussteilen im Leichtbau erfordert eine Berücksichtigung der inhomogenen Werkstoffeigenschaften bereits in der Konstruktionsphase, was aktuell in der Praxis noch nicht vollzogen ist. Durch Kopplung der Prozesssimulation mit der Lebensdauerberechnung sollen eine frühe Bewertung fertigungsbedingter Fehler im Hinblick auf die Schwingfestigkeit erreicht werden und konstruktive Maßnahmen zur optimierten Auslegung abgeleitet werden. Am Beispiel…

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Zellulare Materialien repräsentieren eine Materialklasse, deren strukturbedingte Eigenschaften mit abnehmender Zellgröße immer weiter an Potenzial gewinnen. Daher stellt die Reduzierung der Zellgröße werkstoffübergreifend ein wichtiges Entwicklungsziel dar. Weit fortgeschritten ist man bei Polymeren. Die Herstellung von mikro-zellularen Polymeren ist kommerzialisiert und man arbeitet bereits an der Realisierung nanozellularer Schäume. Ganz anders ist die Situation…

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Die Darstellung komplexer Geometrien lässt den konventionellen Druckguss schnell an Grenzen stoßen. Die Realisierung geometrisch einfacher Hinterschnitte ist nur durch den Einsatz mechanisch aufwendiger und wartungsintensiver  Schiebertechnologien möglich. Aus dem Sand- und Kokillenguss bekannte Sandkerne mit ihren organischen und anorganischen Bindersystemen halten den verfahrensspezifischen Drücken und Geschwindigkeiten nicht Stand und sind deshalb nicht für die…

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Complex 3-D carbon fibre preforms are to be infiltrated with aluminium in a high pressure die casting process. If our approach is successful, it will represent a major breakthrough compared to gas pressure infiltration, the state-of-the-art technology to manufacture fibre reinforced metal parts. Compared to the above mentioned technology, pressure die casting offers several advantages. The short cycle times characteristic for this process are not only of a substantial economic advantage, but also constrict the kinetically controlled deleterious reactions between the fibre-preforms and the aluminium matrix. Based on results of preliminary die casting experiments and numerical simulations of the infiltration process, an advanced mould design was realized in the past project phase further improving fibre preform preheating. In combination with advanced alloy compositions and fibre coatings developed by the project partners the main aims of the proposed continuation are to realize metal matrix composites (MMC) with improved transversal strength and ductility. A detailed understanding of the interface reactions is necessary to relate processing parameters, alloy and coating composition to the mechanical properties of the obtained MMC. In order to rationalise results, advanced microstructural investigations like SEM-FIB, high resolution TEM and numerical calculations of the infiltration process with Flow-3D and ABAQUS are envisaged.

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Das Kernziel des Vorhabens ist ein verbessertes mechanistisches Verständnis der Heißrissbildung bei der Erstarrung von Nickelbasislegierungen. Die Ergebnisse können in einem eventuellen Nachfolgeprojekt zur Entwicklung neuer besser gießbarer Legierungssysteme genutzt werden. Auf Basis umfangreicher Vorarbeiten gehen wir von der Erkenntnis aus, dass die Restschmelze in gut gießbaren Legierungen lokalisiert vorliegt und nicht filmartig verteilt ist. Im Antragszeitraum…

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