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KSM Castings Group
The potential of High Pressure Die Casting for the production of highly stressed components
in automotive applications
Dr. Klaus Greven KSM Castings Group GmbH
2 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
KSM Castings
Motivation
Controlled Vacuum Casting (CVC™)
Potential Applications
Chassis
Body
Agenda
3 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Turnover: ~ 450 Mio. EUR
Employees: ~ 2.900
Production Technologies:
High Pressure Die Casting
Gravity Die Casting
Counter Pressure Casting
Multi-Tilt Casting
Low Pressure Sand Casting
Machining & Assembly
Development Capability:
Simultaneous Engineering
Technology Engineering
System Development
Key Figures
4 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
1 2 3
4
5 7
Hildesheim Headquarters
High Pressure Die Casting
Gravity Die Casting
Machining & Assembly
1 Wuppertal High Pressure Die Casting
Machining & Assembly
2 Radevormwald High Pressure Die Casting
Machining & Assembly
3 Wernigerode Gravity Die Casting
Machining & Assembly
4
Hrádek nad Nisou High Pressure Die Casting
Machining & Assembly
5 Changchun High Pressure Die Casting
Grtavity Die Casting
Machining & Assembly
6 USA High Pressure Die Casting
Permanent Mould Casting
Machining & Assembly
7
USA GERMANY CZECH REPUBLIC
CHINA
6
Global Footprint
5 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Front axle subframe
Cylinder head cover
Transmission housing
Steering gear box
Knuckle Pump housing
Valve body
Cross member (Variostruct)
Pillar - prototype
Pedal bracket
Product Portfolio
6 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
KSM Castings
Motivation
Controlled Vacuum Casting (CVC™)
Potential Applications
Chassis
Body
Agenda
7 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Development of Curb Weight Example VW Golf (weight in kg)
Aluminium Content in Light Vehicles (kg aluminium per vehicle)
167153 148
132 130
95
70
90
110
130
150
170
190
Mercedes VW
Group
GM Toyota EU
Target 2012
EU
Target 2015
CO2 Fleet Emission vs. Regulatory Targets (g CO2 per km)
790890
9601,050
1,155 1,217
0
200
400
600
800
1,000
1,200
1,400
Golf I Golf II Golf III Golf IV Golf V Golf VI
+427 kg / +54%
CY
0
40
80
120
160
200
1980 1985 1990 1995 2000 2005 2010 2015 2020
Source: Roland Berger
Every OEM has the need to reduce weight
Motivation
8 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
powertrain
60%
chassis
38%
body
2%
body
39%
chassis
24%
powertrain
16%
equipment
15%
electrical
system 6%
Typical distribution of mass Aluminum share by application
Chassis: potential for weight saving by design optimization of aluminum components
Body: potential for weight saving by substitution of steel components
Motivation
9 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
KSM Castings
Motivation
Controlled Vacuum Casting (CVC™)
Potential Applications
Chassis
Body
Agenda
10 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Die casting tool
Heat treatment
KSM vacuum piston
Vacuum control
Process control
Main objectives
No restriction concerning process stability
No restriction concerning OEE
Welding of cast parts without surface treatment
Optimized heat treatment concerning distortion
Controlled Vacuum Casting (CVC™)
11 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
CVC
Controlled Vacuum Casting (CVC™)
Heat Treatment Welding
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
9,0
10,0
29 30 31 32 33 34 35 36 37 38 39
po
ro
sit
y [
%]
sample
12 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
0
50
100
150
200
250
300
0 2 4 6 8 10 12 14 16
Yie
ld S
tren
gth
[M
Pa]
Elongation [%]
Gravity Die Casting
HPDC
BIW subframes knuckles
Controlled Vacuum Casting (CVC™)
13 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
KSM Castings
Motivation
Controlled Vacuum Casting (CVC™)
Potential Applications
Chassis
Body
Agenda
14 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Chassis Applications
Characteristics
Product Information
Process: Controlled Vacuum Casting
Material: Aluminum
Alloy: Al Mg5 Si2 Mn
Weight: 7.82 kgs
Volume: 60,000 parts p. a.
Weldable die casting for chassis components
Weldability without any surface treatment
Mechanical properties are achieved in as cast condition
Mechanical Characteristics
Yield strength: YS >270 MPa
Tensile strength: UTS >150 MPa
Elongation: A5 >5 %
Subframe BMW 5,6,7 series 4WD
15 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
0
2
4
6
8
10
12
14
16
020406080
100120140160180200220240260280300320
4385
4444
4553
4652
4811
4915
5109
5230
5392
5410
5464
5666
5690
5702
5775
5891
5996
6071
6117
6243
elo
ngation [
%]
UTS,
YS [
MPa]
sample
UTS YS elongation
UTS [MPa] YS [MPa] elongation [%]
Average 290.2 170.3 9.9
Standard deviation 8.8 5.7 1.8
Chassis Applications
Subframe BMW 5,6,7 series 4WD
17 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Design space
target: minimizing mass
boundary condition: stiffness
target: minimizing stresses
boundary condition: mass, stiffness
Chassis Applications
Rear Knuckle (load per axle ~1.000 kg)
18 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Cast aluminum knuckle
Redesigned CVC knuckle
Weight -22%
Chassis Applications
Series application CVC concept
Rear Knuckle (load per axle ~1.000 kg)
19 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Chassis Applications
Aluminum/Steel Hybrid Wheel Hub
20 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Fe
Al
Chassis Applications
AlSi10MnMg T6
UTS 340
YS 243
elongation 3,7
0
1
2
3
4
5
6
7
8
9
10
0
50
100
150
200
250
300
350
400
Elo
ng
ati
on
[%
]
UTS
, Y
S [
MP
a]
Aluminum/Steel Hybrid Wheel Hub
21 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
KSM Castings
Motivation
Controlled Vacuum Casting (CVC™)
Potential Applications
Chassis
Body
Agenda
22 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
ASAC (Advanced Scalable Aluminum Casting) Variants:
Body Applications
23 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
1
2
10
7 9
6
8 5
4 3
Mass 1
4 3
6
5
2
ASAC Steel
63%
100%
Body Applications
ASAC (Advanced Scalable Aluminum Casting)
24 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Fmax n Fmax
maxB
critB
maxH
critH
b b Rib Rib
Cross section stabilization using ribs in the hybrid structure
Conventional Stamping assembly (B)
Hybrid structure (H)
Potential enhancements in buckling strength
Compressive stress
crit = critical buckling strength
max = maximum buckling strength
b = section profile dimension
Lightweight potential with very high structural performance
Body Applications
25 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
• Material: Steel Stampings
• Construction: 3 piece design
• Assembly: Spot-welding, Laser- welding, Adhesive Bonding
• Material: Al/steel Hybrid
• Construction: 1 piece design
• Assembly: Hybrid Casting (Force- and Form-fit)
Body Applications
26 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Forc
e
Distance
3-point central bending
Test VarioStruct
Test Original117%
135%
72%
100% 100% 100%
0%
20%
40%
60%
80%
100%
120%
140%
160%
Fmax EnergyAbsorption
Weight
VarioStruct Original
Body Applications
27 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications
KSM Castings Group
Weight reduction by target-oriented distribution of mass
Possible weight reduction: app. 20%
Body Applications