Contribution to euroLITE 2007

Innovative lightweight design solutions thanks to multi-material

components

Compound casting less weight, greater costeffectiveness

The lightweight construction philosophy is based on the principle
of making the best possible use of the material. Vehicle
construction and aerospace in particular demand solutions which
save as much weight as possible while fulfilling identical or even
greater requirements with regard to component properties, and
which can be produced at low cost. Compound casting meets a
wide range of requirements within one component by combining
different materials. In addition to saving weight, it has the added
advantage of reducing bonding processes.
In the product creation process, lightweight construction solutions can be
implemented in the design phase, the construction phase itself and the
manufacturing phase. The construction phase also offers great weightsaving potential through the selection of the right material. Often,
however, different things are required of a component or the material
used with regard to strength, corrosion or heat resistance for instance.
Components constructed using a hybrid method have proven to offer a
useful approach.
Compound casting multi-material construction with savings
potential
One variant which is becoming ever more important in series production
is compound casting. Through the combination of various materials, this
compound casting process can help components meet the most diverse
of requirements. And with the hybrid construction process, the material
bond is created by recasting separate hot or cold bonding/jointing
processes are not necessary. This in turn reduces the number of
production steps needed in the manufacturing process. A good example

of applications in this field is the manufacturing of engine blocks. As a

pure sheet steel solution, it consists of numerous individual parts which
are joined to one another. In contrast, the compound casting solution
makes it possible to produce this component as a single piece. The
intelligently designed casting made from an aluminium or magnesium
alloy ensures the high functional integrity of flanges and bearing carriers,
for instance. In difficult areas, a carefully positioned insert such as a
semi-finished product made of steel or an aluminium alloy provides the
necessary strength. "In comparison with conventional diecasting, the
manufacture of a compound casting piece requires additional handling,
for example manipulation of inserts or perhaps pretreatment of the
surfaces", explains Werner Fragner, head of casting technology at ARC
LKR Ranshofen GmbH (Austria).
Considering compound casting in the design phase
In order to optimise the weight-saving aspect and strength of the
component with as little manufacturing work as possible, the compound
casting design must be taken into consideration as early as the design
phase of a mixed-material component. The simulation of the casting
process and the evaluation of the compound strength using structural
FEM calculations make it possible to precisely tailor the manufacturing
process and the properties of the component to suit requirements. "In
addition to finding the optimal design of the geometries and parameters
for the casting process, parameters can be determined for calculating
the component strength. This prevents critical flaws in the components",
explains the expert in lightweight construction.
Three types of multi-material compound
With form closure, force closure and adhesive bonding, compound
casting enables three different types of multi-material connection. While
form closure is ensured by the geometric design of the workpiece to be
cast, force closure is based on the solidification shrinkage of the casting
material and generates a press fit. The adhesive bond is created by a
chemical reaction between the liquid material and the insert and ensures

a smooth transition between the materials. "Ideally, at least two of the

connection types are combined in the design of the compound casting
parts", says Fragner.
Each

of

these

material

connections

has

its

advantages

and

disadvantages. The ideal connection must therefore be defined

individually for each component to be designed. A form closure may lead
to a loosening of the connection under dynamic loads, yet it has great
static strength. A force closure is only possible if the component can be
completely transfused. With adhesive bonding, the properties of the
intermetallic phases play an essential part in the quality of the material
bond.
Assessing the material bonds
The project "Austrian Light Weight Structures" (ALWS), managed by
LKR, deals with the assessment of these material bonds. It examines
the potential and the challenges faced throughout the entire product
lifecycle, from manufacturing with innovative designs to specially
designed recycling. In addition to design guidelines, the aspects of
corrosion protection, which is particularly important when two or more
different metallic materials are used, manufacturing parameters, usability
and mechanical and dynamic properties play an important role. For form
closure, for instance, the optimal suitability of different geometries is
examined; with force closure the length and thickness of the connection
points are optimised; and with adhesive bonding the kinetics and
morphology of the chemical bond are characterised.
Compound casting in use
Compound casting parts are already used in vehicle construction for
parts of the chassis, such as the engine block, shock strut supports and
gearbox casing, as well as bodywork components, for example A- and
B-columns, door frames and connection supports and as dashboard
mounts in the interior. And according to information from the automotive
industry, multi-material components are on the increase. This is proven

by compound cast parts such as the 6-cylinder magnesium engine with

aluminium insert from BMW and other components which are
undergoing development but have not yet been announced. The aircraft
industry, too, is relying more and more on compound cast materials.

Info box
euroLITE, international specialist trade fair for lightweight design
The euroLITE international specialist trade fair for lightweight design is
the industry- and technology-independent trade fair platform for the
forward-looking growth market of lightweight construction. The exhibition
portfolio covers software for calculation, simulation and lightweight
construction methods, materials, prototype and model construction,
manufacturing technologies, bonding and connection technology as well
as surface technology, component tests and series production of
lightweight components and semi-finished products. The lightweight
construction trade fair, where LKR will be appearing, is the only one of
its kind in Europe and will be held from 26 to 28 June 2007 in Salzburg.
For more information, visit www.eurolite-expo.eu.

The geometry for form-closed multi-material components in compound

casting is optimised using the finite element method.

Prototype casts with close-to-production casting machines enable the

insert and casting parameters to be optimised.

The development of the thickness of intermetallic phases in aluminiumsteel composites.

Contact addresses:
ARC Leichtmetallkompetenzzentrum Ranshofen GmbH
Werner Fragner
Postfach 26
A-5282 Ranshofen, Austria
Tel: +43 (0)7722 83333-0
Fax: +43 (0)7722 83333-1
Office.lkr@arcs.ac.at
H & K Messe GmbH & Co. KG
Wieland Kniffka
Kaiserstrae 142-144
D-76133 Karlsruhe, Germany
Tel: +49 (0)721 570444-00
Fax: +49 (0)721 570444-22
w.kniffka@hundkmesse.de
SCHULZ. PRESSE. Text
Doris Schulz
Martin-Luther-Strae 39
D-70825 Korntal, Germany
Tel: +49 (0)711 854085
Fax: +49 (0)711 815895
E-mail: ds@pressetextschulz.de