Lightweight Aluminum Broschure - GKN · Market Drivers G KN’s lightweight technology minimizes...
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ALUMINIUM TECHNOLOGY HIGH-PERFORMANCE ALUMINUM TECHNOLOGY Lightweight Aluminum in Powder Metallurgy
Transcript of Lightweight Aluminum Broschure - GKN · Market Drivers G KN’s lightweight technology minimizes...
ALUMINIUM TECHNOLOGYH I G H - P E R F O R M A N C EA LU M I N U M T E C H N O LO GYLightweight Aluminum inPowder Metallurgy
CO2 emissions and fuel economy standards are mandating vehicle mass reduction
Internal combustion engines and hybrid electric vehicle efficiency hinges on smaller engine size, increased transmission speed
Reduction in mass reduces energy use for all forms of energy: ICE, Hybrid, and Electric
LIGHTWEIGHT TECHNOLOGYTHE MARKET’S DRIVE TOWARD LIGHTWEIGHT TECHNOLOGY
Passenger car CO2 emissions and fuel consumption, normalized to NEDC
2000 2005 2010 2015 2020 2025
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s CO
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er, n
orm
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ed to
NED
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Passenger car CO2 emissions and fuel consumption, normalized to NEDC
Mexico 2016: 145
Japan 2020: 122
KSA 2020: 142Brazil 2017: 138
China 2020: 117
India 2022: 113
S. Korea 2020: 97EU 2021: 95 US 2025: 97
Canada 2025: 97
historical performanceenacted targets
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Market Drivers
GKN’s lightweight technology minimizes component mass without compromising performance
GKN’s advanced Powder Metallurgy (PM) technology produces high-strength, net-shape parts geared toward ICE, hybrid and vehicle electrification
GKN is the leader in PM technology and develops lightweight, high-performance Aluminum materials and products
GKN Solutions
Graph/The International Council in Clean Transportation
GKN ALUMINUM MMCUnrivaled Design Freedom
Unique part geometries
Simplified product design without compromised functionality
High material utilization greater than 90 percent
Rapid prototype development, scalable to high- volume production
Aluminum Metal Matrix Composite (Al MMC) Technology
Hard ceramic, uniformly distributed within tough Al-alloy matrix
Improved static and dynamic performance over conventional Al-alloys
Readily forgeable, significantly increasing mechanical performance
Novel Al-Alloy with High Thermal Conductivity (TC2000 series)
Versatile material for thermal management applications
PRODUCT
Heat Management
Transmissions
Hydraulic
Engines
Net shape E�ciency Inertia Thermal Mass
COMBINING EFFICIENT PROCESSING WITH ADVANCED LIGHTWEIGHT MATERIALS
TM
Why Powder Metal lurgy? Why GKN?
GKN‘s ALUMINUM MMCMATERIALS –GKN‘S ALUMINUM MMC
Specif ic Strength
Higher strength-to-weight ratio, allowing for mass reduction and improved vehicle efficiency
Superior resistance to sliding wear for use in hydraulic applications
CTE match with aluminum housing improves overall pump efficiency
Wear Scar (mm)
0 2 4 6 8
Cast Iron
Al PM MMC
Al B390 Die Cast Alloy
Al A380 Die Cast Alloy
Al 6061-T6511 Wrought Alloy
Wear Scar Width (mm)
Increasing Wear Resistance
-0,03 -0,02 -0,01 0
Mass Change of Ring (g)
Weight Change of Block (mm)
Weight change of Ring (mm)
Cast IronAl PM MMC 1.467 0.0000 -0.0015
Al B390 Die Cast Alloy 1.954 0.0001 -0.0126
Al A380 Die Cast Alloy 3.387 -0.0031 -0.0023
Al 6061-T6511 Wrought Alloy 6.587 -0.0234 -0.0214
Al 6061 -T6511
Cast AIA380
Cast AIB390
Al PM MMC
Cast Iron
Wear Scar Width (mm)
3.387
6.587
0.701
1.9541.467
0.0023
0.0214
0.0001
0.0126
0.0015
ASTM G77 – Block-on-Ring Wear Test
Wear Scar (mm)
0 2 4 6 8
Cast Iron
Al PM MMC
Al B390 Die Cast Alloy
Al A380 Die Cast Alloy
Al 6061-T6511 Wrought Alloy
Wear Scar Width (mm)
Increasing Wear Resistance
-0,03 -0,02 -0,01 0
Mass Change of Ring (g)
Weight Change of Block (mm)
Weight change of Ring (mm)
Cast IronAl PM MMC 1.467 0.0000 -0.0015
Al B390 Die Cast Alloy 1.954 0.0001 -0.0126
Al A380 Die Cast Alloy 3.387 -0.0031 -0.0023
Al 6061-T6511 Wrought Alloy 6.587 -0.0234 -0.0214
Al 6061 -T6511
Cast AIA380
Cast AIB390
Al PM MMC
Cast Iron
Wear Scar Width (mm)
3.387
6.587
0.701
1.9541.467
0.0023
0.0214
0.0001
0.0126
0.0015
ASTM G77 – Block-on-Ring Wear Test
Wear Resistance
Forging specific strength exceeds steel PM alloys and forgings
Minimized oil conta-mination (no abrasive Si particles), improved pump efficiency
Steel Forged Alloys
Steel PM Distaloys
Ti-6Al-4V-Wrought Alloy
Al Aerospace-Grade MMCs
Al Forged MMC
Al PM MMC
Al Die Cast Alloys
Specific Strength Tensile [(MPa)/(g/cm3)]
0 50 100 150 200 250
Steel Forgings
Steel PM
Distaloys
TitaniumForgings
AerospaceAl MMCs
GKN's Al Forged
MMC
GKN's Al PM MMC
Al Castings
Specific Strength Tensile [(MPa)/(g/cm3)]
87
232
74
ρ σUTS Specific
(g/cm3) (MPa)
Al Die Cast Alloys 2.7 234 87Al PM MMC 2.7 325 120Al Forged MMC 2.7 450 167Al Aerospace -Grade MMCs 2.8 650 232Ti-6Al- 4V Wrought Alloy 4.5 1000 222Steel PM Distaloys 7 520 74
Steel Wrought Alloys 7.9 1000 127
(σUTS/ρ)
127
222
167
120
Mat
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Formability
GKN ALUMINUM TC2000M AT E R I A L S – G K N ’ S A LU M I N U M T C 2000 S E R I E S
Thermal Conductivity
225
Pure Aluminum
Al PM TC2000
AI 6063
AI 6061
Cast AI A380
Thermal Conductivity (W/m-K)
234
218
180
96
Qualitative Benefits
Unique, net-shape geo-metries with excellent tolerance control without costly machining
Green
Minimal material scrap and com-pletely recyclable material, mini-mizing environmental impact
Manufacturability
High productionvolumes withreliable performance
Design
GKN engineers use modeling and simulation to ensure opti-mized designs, meeting customer requirements
GKN’s TC2000 is the PM counterpart to commercially pure, wrought aluminum. TC2000 outperforms conventional extrusions and castings by limiting solute impurities within the alu- minum matrix.
OUR SOLUTIONSL I G H T W E I G H T A P P L I C AT I O N S
Camshaft Bearing Caps
GKN Powder Metallurgy produces over 30 million engine camshaft caps per year, designed to exceed unique customer requirements. Several material options allow for design flexibi-lity to optimize geometric precision, strength, toughness, wear resistance and/or cost.
GKN’s PM netshape design only requires customer line bore
High wear and fatigue resistance (with optional MMC material)
Unique Z-loc, for dowel elimination
Planetary Reaction Carrier
Introduction of aluminum reduced the mass of the carrier application by 1 kg
High wear resistance and lower inertial mass
Maintains strength and fatigue at operating temperature of 150 degrees Celsius
Industry-winning dimensional precision
This MPIF award-winning Planetary Reaction Carrier is the first commercial use of powder metal Aluminum MMC material for a carrier application. The technology won the 2018 Grand Prize in the MPIF Design Excellence Awards.
OUR SOLUTIONSL I G H T W E I G H T A P P L I C AT I O N S
Forged Products
Tailored preform design allows for highly controllable plastic flow
Near-net shape, and economical process eliminates subsequent working operations
Fatigue properties exceed wrought forged Aluminum
Conventional Forged Material GKN’s Forged MMC Material
GKN is in production development of Aluminum forged products:
OUR SOLUTIONSL I G H T W E I G H T A P P L I C AT I O N S
Ben
ding
Stre
ss (+
/- M
Pa)
Bending Fatigue Strength
400
350
300
250
200
150
100
1,E+03 1,E+051,E+04 1,E+06 1,E+07 1,E+08
GKN´s 2618 MMCWrought 2618
number of cycles
Heat Sink
Unique tower and three section sizes, not practical for casting or extrusion
Higher thermal conductivity, requiring less thermal mass
No machining required, providing cost savings
High ductility, reducing risk of cracking during mechanical attachment
GKN‘s heat sink was developed to replace diecast components for a car radio cooling application.
OUR SOLUTIONSL I G H T W E I G H T A P P L I C AT I O N S
OUR SOLUTIONS
© GKN Powder Metal lurgy 2018
Alan TaylorLightweight Technology
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ALUMINUM TECHNOLOGY
