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Use of Selective Laser Melting (SLM) as a Replacement for Pressure Die Casting Technology for the Production of Automotive Casting

Piekło J., Garbacz-Klempka A.

Archives of Foundry Engineering

2021

Vol. 21, iss. 2

9--16

Selective laser melting is one of the additive manufacturing technologies that is used to produce complex-shaped components for applications in the automotive industry. The purpose of the changes in the design, technology, and material tests was to make a steering gear housing using the SLM method. The steering gear housing was produced by the pressure casting method using an AlSi9Cu3(Fe) alloy. The construction of this housing is adapted to the specifics of left-hand traffic. The change in technology was related to the change of the position of the steering system from right-hand to left-hand and the demand for a limited number of gear housings. It was necessary to make a virtual model of the housing on the basis of the part that was removed from the vehicle. In SLM technology, the AlSi10Mg aluminum alloy was used as a raw material in the form of CL 32Al gas-atomized powder. After the SLM process was completed, the housings were subjected to heat treatment. The AlSi10Mg alloy fabricated by the SLM method after heat treatment is characterized by good plasticity and an average value of tensile strength. The last stage was to check the geometry of the SLM housing with a 3D scanner. As a result, a map of the dimensional deviations from the nominal values was obtained. This data was used to modify the CAD model before the next fabrication process. The use of 3D printing technology allowed for the quick production of elements. The time to develop the technology and the production of the first two gear housings based on a 3D model was seven days.

Zastosowanie żeliwa białego na odlewy motoryzacyjne

Trepczyńska-Łent M.

Logistyka

2015

nr 4

2136--2142, CD2

Celem artykułu jest przedstawienie możliwości doboru składu chemicznego żeliwa białego i kształtowanie struktury tego materiału. Różnorodność występujących węglików i rozmieszczenie ich w osnowie żeliwa, daje możliwości otrzymania własności pożądanych dla części motoryzacyjnych. Prezentowane dane potwierdzają zależność między składem chemicznym żeliwa białego stopowego a jego własnościami eksploatacyjnymi.

The aim of this article is to present the possibilities of selection of the chemical composition of white cast iron and forming a material structure. Diversity and distribution of carbides present in the matrix of iron, gives the possibility of obtaining the required properties for automotive parts. Conducted data confirm the relationship between the chemical composition of the alloy white cast iron and its exploitation properties.

Microstructure analysis of the automotive Al-Si-Cu castings

Krupiński M., Dobrzański L. A., Sokolowski J. H.

Archives of Foundry Engineering

2008

Vol. 8, iss. 1

71-74

The developed design methodologies both the material and technological ones will make it possible to improve shortly the quality of materials from the light alloys in the technological process, and the automatic process flow correction will make the production cost reduction possible, and - first of all - to reduce the amount of the waste products. In the metal casting industry, an improvement of component quality depends mainly on better control over the production parameters. Castings were analysed in the paper of car engine blocks and heads from the Al-Si-Cu alloys of the AC-AlSi7Cu3Mg type fabricated with the "Cosworth" technological process. In this work the AC-AlSi7Cu3Mg alloy structure was investigated, of this alloy samples were cut of for structure analysis of the cylinder part as well of crankshaft of a fuel engine. The investigation shows a difference in the (phase) structure morphology as a result of cast cooling rate.