Lost Core

New Perspectives in Die Casting

Dario Pierri, Bhler AG

1 | Bhler | Lost Core | 2012

Content
Short companys presentation Potential of die casting with lost core technology Die casting with lost core as compared with permanent mold and sand casting Advantages of die casting with lost core Process steps for producing parts with lost core technology

2 | Bhler | Lost Core | 2012

Bhler - A 150-year success story

Global leader with strong local roots
Technology partner for machines, systems and services for processing basic foods and for producing high-quality materials. Present in over 140 countries. Over 70 sales & service companies, more than 20 manufacturing sites and 24 service stations around the world. Annual sales 2011: 1,760 million. Number of employees: 8,800. High innovation rate. 100 % family owned.

3 | Bhler | Lost Core | 2012

OEMs requirements for engine block

Resistant to high pressure and high temperature due to high charged engines (downsizing) Cost efficiency & low cycle time Lightweight Designs freedom for cooling channels and for necessary reinforcing ribs

4 | Bhler | Lost Core | 2012

Lost Core Technology

New design opportunities and expanded parts spectrum

Advantages of die casting with Lost Core Complex internal shaping - undercuts Integral design: New combinations of functions and components New part design opportunities for die cast parts (e.g. Closed-deck motors)

Turbo charger (cold side)

3D-Freiformkanle-Projekt

5 | Bhler | Lost Core | 2011

Lost Core Technology

Transferring parts from other casting technologies to die casting

Die casting with Lost Core as compared with permanent mold and sand casting Savings of material due to thin-walled parts Higher degree of productivity due to shorter cycle times for die casting Less machining after casting
Water outlet Source: Bocar

Higher cost effectivness by using Lost Core technology

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Lost Core Technology

Customers benefit

higher productivity reduction of material (lightweighting)

less machining

up to 15% cost advantage*

*Source: Bocar Mexico
compared to permanent mold casting

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Process steps
Overview

Salt core produced out of liquid phase

Aluminium is casted around the salt cores

Remove salt cores

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Process steps
First step: salt core produced out of liquid phase
Salt cores production Salt cores production process is similar to standard die casting process Process is full automated Salt mixture is optimised for: - increasing the strength - minimising the costs Thermal optimization of the process for high quality salt cores
Casted salt core

9 | Bhler | Lost Core | 2012

Process steps
Second step: aluminium is casted around the salt core
Shot is real-time controlled. This is very important in order to avoid the breaking of the inserted salt cores. The correct core support is relevant know-how. FSISimulation (Fluid Structure Interaction) optimises the position between salt core and the casted aluminium in order to minimize the impact forces on the salt core.

Aluminium part with salt core inside

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Process steps
Second step: aluminium is casted around the salt core

Lost_core_full_aut omatic_cycle

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Process steps
Third step: remove salt cores
Efficient removal process tremoval < tproduction_salt_core Low water consumption Low economic impact on process costs High recycling rate of salt material Only a low percentage of salt is dissolved in water. Uncritical for environment as long as pH-value is below 8 Process is full automated

Aluminium part after removing the salt core

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Process steps
Third step: remove salt cores

robot arm Seperator water-salt nozzles

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Process steps
Third step: remove salt cores

DSCN3702

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Salt Core Simulation.

Results of filling simulation.
Prediction of potential air porosity.

Simulation result shows potential areas for air porosity.

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Salt Core Simulation.

Solidification.
Prediction of potential shrinkage porosity. Simulation successfully validated by casting examples.

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Lost Cores technology meets requirements for engine block

Cost efficiency & low cycle time Lightweight Resistant to high pressure and high temperature due to high charged engines (downsizing) Designs freedom for cooling channels and for necessary reinforcing ribs Bhler supports you with: the optimal die casting machine optimized peripherals the necessary process know-how

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Backup

18 | Bhler | Lost cores | 2011

Lost Core Technology

New design opportunities and expanded parts spectrum

Advantages of die casting with Lost Core Complex internal shaping - undercuts Integral design: New combinations of functions and components New part design opportunities for die cast parts (e.g. Closed-deck motors)
Compare: open/closed deck Source: VW

Innovative approaches for die casting

19 | Bhler | Lost Core | 2012

Aluminum Simulation.
Results of FSI Simulation.
Ingate velocity has an influence on core viability. Intensification pressure may not be applied before the cavity is filled completely.
5,00E+07 4,50E+07
Mean Iso Stress @ 0.7 m/s Mean Iso Stress @ 1.4 m/s Mean Iso Stress @ 2.1 m/s Ingate Velocity @ 0.7 m/s Ingate Velocity @ 1.4 m/s Ingate Velocity @ 2.1 m/s

140 120 100 80 60 critical stress 40 20 0 2,220

Mean Iso Stress [Pa]

3,50E+07 3,00E+07 2,50E+07 2,00E+07 1,50E+07 1,00E+07 5,00E+06 0,00E+00 2,170

2,180

2,190

2,200

2,210

Filling Time t [s]

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Ingate Velocity [m/s]

4,00E+07