Latest trends in materials technology supporting automotive innovation

JSAE Exposition 2018: Aluminum processing, dissimilar metals bonding, metal casting 3D printers

2018/06/26

Summary

This report is a summary of the forum presentations on "Trends in Material Technologies and Automotive Innovation II -Through Lightweight Metals and Chemicals" given during the 27th Automotive Engineering Exposition 2018 Yokohama". (Sponsored by the Society of Automotive Engineers of Japan, Inc., held at the PACIFICO Yokohama from May 23-25, 2018)

 

Latest trends in materials technologies for motorcycles (Yamaha Motor Co., Ltd.)

Two-wheeled vehicles, especially super sports models, must be compact, lightweight and high performance, so technologies developed from motorcycle racing are being applied to vehicles sold for the mass market. On these vehicles, materials such as aluminum, magnesium and titanium are used in high precision processing and surface treatment technologies. Furthermore, in recent years, motorcycles are expected to contribute to protecting the environment, so Yamaha has been working towards improving fuel economy, reducing emissions, and vehicle electrification.

 

Attempt to create innovative interfaces with high performance during Al/Fe dissimilar metals bonding (Tohoku University)

Replacing portions of steel with aluminum alloys to reduce the weight of structures by multi-materialization is gaining attention in the automotive industry. Dissimilar metals bonding of aluminum and steel is an essential technology for weight reduction, but the bonding interface of dissimilar metals have a weak Fe-Al intermetallic compound (IMC) layer that is problematic due to a significant lowering of the mechanical properties of the materials. This presentation reported the result of studies of countermeasures conducted.

 

アルミダイカスト部品
Ryobi's exhibition at JSAE Exposition 2018

Development of thick-walled aluminum parts manufacturing technology using pressurized die-mold casting (Ryobi Limited)

Weight reduction in vehicles contributes to fuel economy improvements, and the substitution of aluminum alloys for traditional cast iron materials is becoming a common practice. The materials used for suspension parts such as knuckles made of cast iron are being replaced aluminum alloy materials that result in a weight reduction of 30-50%, increasing the demand for these materials. However, the diecast method is not suitable for large products like knuckles with variations in wall thickness, and other methods suitable for thick-walled products such as gravity casting, low-pressure casting, and squeeze die casting, as these are considered expensive.
Ryobi has developed the GD squeeze casting method suitable for thick-walled parts that makes it possible to achieve high quality casting with short cycle times using compact equipment.

 

Evolution and outlook of 3D printers related to light metal processes (National Institute of Advanced Industrial Science and Technology, AIST)

Traditionally, 3D printers have been used as a rapid prototyping technology centered on stereolithography to mold resin materials, check shapes, and to perform functional evaluation of designs. However, although the usage of 3D for rapid prototyping has decreased, it is starting to expand to practical applications for the manufacturing of parts and other products. This section summarizes the issues and outlook involving metal forming 3D printers intended for metal parts manufacturing.

 

Related reports:
JSAE Exposition 2018: Lightweight processing technology and plastic materials (May 2018)
Automotive World 2018: Joining of dissimilar materials, high function plastics exhibition (Feb. 2018)
Automotive World 2018: CFRP components and plastic molding technology (Feb. 2018)