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Automobile steel material parts substitution with aluminium

The target is the manufacturing of efficient aluminium (al) engines, cylinders, disc wheels, etc. The substitution of automobile steel parts with corresponding ones manufactured using al will be investigated.

The wide use of aluminium in the automotive industry brought significant advantages, such as the reduction in the weight of parts, fuel consumption and emissions reduction, as well as their efficiency increases. Manufacturing of aluminium parts is a demanding task, when high accuracy parts within limited tolerances are required. Furthermore, the production of aluminium parts with high mechanical strength and especially fatigue strength is not always an easy feat. In the frame of the present project, various automobile parts will be constructed of aluminium alloys by means of various advanced manufacturing techniques and will be tested for their efficiency. 2.1.1 An aluminium disc wheel is a significant part, which will be constructed through semi-solid moulding of Al according to the following tasks: * Disc wheel redesign in order to be constructed of Al-materials and examination of its loading using FEM (Finite Element Method) techniques. * Analytical-experimental optimisation of the conduction heating of aluminium. * Simulation of the moulding procedure and construction of the required matrices for the semi-solid moulding of aluminium. * Semi-solid moulding of aluminium considering the optimised conditions previously determined for the construction of the Al disc wheel prototype. * Quality control of the produced aluminium parts for the monitoring of the achieved geometrical and mechanical strength properties. * Real conditions testing of the manufactured aluminium disc wheels to determine their performance efficiency. 2.1.2 A second product to be constructed of Al, in the frame of the present project, is a motor block. The development of a new Al-engine with variable compression ratio (10 - 15) is demanded, following requirements from the European Parliament to reduce the CO2 emission from vehicles to 120 g/km by 2005. The programme of developing the batch manufacturing of this engine comprises three stages of development, research and manufacturing activities. 2.1.2.1 Development (design, construction and manufacture of the "0" series of engines): * Preparation of the construction documentation for the engine for the batch production based on the prototype documentation, as well as producing the specification for the new or standard engine parts. The production of the majority of new parts is predicted to be with corresponding types of aluminium alloys. * Selection of technological procedures and design of technological documentation for machining the new parts made of aluminium, as well as design of the new procedures for the engine assembly. * Manufacture of the new aluminium parts and procurement of standard parts that make up the engine. 2.1.2.2 Research associated to the project tasks: * Selection of aluminium alloys for manufacturing the new engine parts and other possible vehicle elements (substitution of parts made of steel and gray cast iron). * Selection of the optimum machining conditions from aspects of productivity, quality of contact layers of the aluminium parts and ecology. * Selection of the optimum procedures for improving the quality of the contact layers of the aluminium parts (coatings, etc.) from aspects of tribology and functioning reliability in the development of engines and vehicles. * Engine testing on test stands and in vehicles on the road (road tests). 2.1.2.3 In the area of production the following activities are foreseen: * Manufacture of the engine and vehicle parts made of aluminium alloys (substitution of steel and gray cast iron) with a selection of cutting tools, machines and cutting fluids according to optimum conditions defined in the technological documentation. * Assembly of the "0" series of engines and their assembly on the selected vehicles. Keywords: aluminium, manufacturing, automobile.
Acronym: 
ASMATA
Project ID: 
3 240
Start date: 
01-01-2004
Project Duration: 
24months
Project costs: 
670 000.00€
Technological Area: 
Metals and Alloys
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.