CASE STUDY

AMPCOLOY 972 as a plate on BIW fixtures

Overview:
Purpose of this case study is to analyse the excellent mechanical properties of AMPCOLOY 972 material as a
plate on BIW fixtures.

AMPCOLOY 972 Plates on BIW fixtures

Also to address following points:

Life of the plates made out of AMPCOLOY 972

Reduction in cleaning efforts and time

In the BIW fixture, during spot welding operation, high conductive CrCuZr plates are used to weld the frame
components. Currently OEMs are purchasing local CrCuZr plates.
Local CrCuZr plates have poor mechanical properities with porosity and blow holes in the material. This results of
formation of very rapid dants on the plate during opetaion with very less life.
We have taken their existing plate and checked the hardness and conductivity inhouse. Following were the
results:
Hardness 98 (In HBW 10/3000), Conductivity 70.99 (IN % IACS)
We suggested them AMPCOLOY 972 which has following mechanical properties:
Hardness 151 (In HBW 10/3000), Conductivity 85 (IN % IACS)

AMPCO METAL INDIA PVT. LTD.

Chakan, Pune 410501, Maharashtra INDIA

Trials:
We have given one AMPCOLOY 972 plate (9 x 32 x 102 mm) for trial on 14/09/2016 to Mahindra Vehicle
Manufacturer Limited. Till today the plate is working amazingly superb with no dant.

AMPCOLOY 972 plate on

trial for more than 8 months

Findings:
Following problem was identified while using local CrCuZr plate:
1) Rapid dants on the plate results in poor weld quality and component rejection and rework.
2) Less life due to low hardness and conductivity.
3) One additional operation for cleaning of the plates (center cleaning and refinishing) results in loss of time
and efforts.
Plates made in local CrCuZr

Plates made in AMPCOLOY972

Very less life approx. 02 months

Repeatative dants on the plate after 1 week
Poor mechanical properties (Low hardness and conductivity)
High downtime for cleaning and finishing after every 2 days
In criticle areas poor weld quality

Very high life (on trial for more than 08 months - no dant)
No dants
Rich mechanical properties (High hardness and conductivity)
Clean and finish once in a 15 days
Good weld quality

Observations:

Life of existing CrCuZr plates was maximum 02 Months.

Life of AMPCOLOY 972 plate was more than 08 months as the trials are still going on.
Releatitive dants on existing CrCuZr plate after every 2 days
No dant on AMPCOLOY 972 plate
Quality issues related to weld quality with existing plate, with AMPCOLOY 972 no quality related isses.

Conclusions:
About
300% more life
than existing
plate

AMPCO METAL INDIA PVT. LTD.

Chakan, Pune 410501, Maharashtra INDIA

Zero dants on
AMPCOLOY 972

plate

No repeatative
cleaning of the
plate saves time
and efforts

No quality related
concerns in case
of
AMPCOLOY 972

Graphical Comparision :

Recomandation from Mahindra:

AMPCO METAL INDIA PVT. LTD.

Chakan, Pune 410501, Maharashtra INDIA