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Lightweight Aluminum Broschure

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Lightweight Aluminum Broschure ALUMINIUM TECHNOLOGY HIGH-PERFORMANCE ALUMINUM TECHNOLOGY Lightweight Aluminum in Powder Metallurgy THE MARKET’S DRIVE TOWARD LIGHTWEIGHTLIGHTWEIGHT TECHNOLOGY TECHNOLOGY Market Drivers Passenger car CO2 emissions and fuel consumption, normalized to NEDC CO2 emissions and fuel economy standards are Passenger car CO2 emissions and fuel consumption, normalized to NEDC mandating vehicle mass reduction 220 Internal combustion engines and hybrid electric 200 - 9 vehicle efficiency hinges on smaller engine size, increased transmission speed 180 - 8 Reduction in mass reduces energy use for all 160 - 7 forms of energy: ICE, Hybrid, and Electric KSA 2020: 142 140 Mexico 2016: 145 Brazil 2017: 138 - 6 China 2020: 117 GKN Solutions 120 Japan 2020: 122 - 5 India 2022: 113 100 S. Korea 2020: 97 US 2025: 97 GKN’s lightweight technology minimizes component EU 2021: 95 Canada 2025: 97 - 4 mass without compromising performance 80 per kilometer, normalized to NEDC 2 - 3 GKN’s advanced Powder Metallurgy (PM) technology 60 produces high-strength, net-shape parts geared historical performance 40 - 2 Grams CO toward ICE, hybrid and vehicle electrification enacted targets Liters per 100 kilometers (gasoline equivalent) GKN is the leader in PM technology and develops 20 - 1 lightweight, high-performance Aluminum materials and products Year 2000 2005 2010 2015 2020 2025 Graph/The International Council in Clean Transportation COMBINING EFFICIENT PROCESSING GKNWITH ADVANCEDALUMINUM LIGHTWEIGHT MMC MATERIALS Why Powder Metallurgy? Why GKN? Unrivaled Design Freedom Aluminum Metal Matrix Composite (Al MMC) Technology Unique part geometries Hard ceramic, uniformly distributed within tough Al-alloy matrix Simplified product design without compromised Improved static and dynamic performance over conventional Al-alloys functionality Readily forgeable, significantly increasing mechanical performance High material utilization greater than 90 percent Rapid prototype development, scalable to high- Novel Al-Alloy with High Thermal Conductivity (TC2000 series) volume production Versatile material for thermal management applications TM PRODUCT Net shape Eciency Inertia Thermal Mass Heat Management Transmissions Hydraulic Engines Specific Strength Tensile [(MPa)/(g/cm3)] -0,03 -0,02 -0,01 0 Steel Forged Alloys Wear Scar Width (mm) Al 6061-T6511 Wrought Alloy Steel PM Distaloys Wear Scar Width (mm) -0,03 -0,02 -0,01 0 Ti-6Al-4V-Wrought Alloy Al A380 Die Cast Alloy Al 6061-T6511 Wrought Alloy Al Aerospace-Grade MMCs Al B390 Die Cast Alloy Al A380 Die Cast Alloy AlMATERIALS Forged MMC – Al PM MMC Al PM MMC Al B390 Die Cast Alloy GKN‘S ALUMINUM MMC Cast Iron Al Die Cast Alloys Al PM MMC 0 2 4 6 8 GKN‘s0 50 ALUMINUM 100 150 200 250 MMC Cast Iron Specific Strength 0 Wear2 4 Resistance6 8 ASTM G77 – Block-on-Ring Wear Test 6.587 Specific Strength Tensile [(MPa)/(g/cm)] ASTM G77 – Block-on-Ring Wear Test Increasing Wear Resistance 6.587 3.387 Increasing Wear Resistance Wear Scar Width (mm) 1.954 232 222 1.467 3.387 0.701 167 Wear Scar Width (mm) 1.954 127 120 1.467 0.701 87 Al 6061 - Cast AI Cast AI Al PM Cast 74 T6511 A380 B390 MMC Iron Al 6061 - Cast AI CastM aAIss ChaAnl PgMe of RingC (agst) Steel Steel Titanium Aerospace GKN's GKN's Al T6511 A380 B390 MMC Iron 0.0023 0.0015 0.0001 Forgings PM Forgings Al MMCs Al Forged Al PM Castings Materials Distaloys MMC MMC 0.0126 Mass Change of Ring (g) 0.0023 0.0015 0.0001 0.0214 0.0126 0.0214 Higher strength-to-weight Forging specific strength Superior resistance Minimized oil contaWear Sc-ar Weight CCTEhange match Weight cwithhange ρ σUTS Specific ratio, allowing for mass exceeds steel PM alloys to sliding wear for (mm) of Block (mm) of Ring (mm) 3 mination (no abrasive aluminum housing (g/cm ) (MPa) (σUTS/ρ) Cast Iron reduction and improved and forgings use in hydraulic Si particles), improved improves overall Al Die Cast Alloys 2.7 234 87 Wear Scar WeighAt lC PhMan MgeM CWeight change 1.467 0.0000 -0.0015 Al PvehicleM MMC efficiency 2.7 325 120 applications(mm) of BloAckl B (m39m0) Die oCfapump Rsti nAgll o(mym efficiency) 1.954 0.00pump01 efficiency-0.0126 Al Forged MMC 2.7 450 167 Cast Iron Al A380 Die Cast Alloy 3.387 -0.0031 -0.0023 Al PM MMC 1.467 0.0000 -0.0015 - - Al Aerospace-Grade MMCs 2.8 650 232 Al 6061-T6511 Wrought Alloy 6.587 0.0234 0.0214 Al B390 Die Cast Alloy 1.954 0.0001 -0.0126 Ti-6Al-4V Wrought Alloy 4.5 1000 222 Al A380 Die Cast Alloy 3.387 -0.0031 -0.0023 Steel PM Distaloys 7 520 74 Al 6061-T6511 Wrought Alloy 6.587 -0.0234 -0.0214 Steel Wrought Alloys 7.9 1000 127 MATERIALS – GKNGKN’S ALUMINUMALUMINUM TC2000 SERIES TC2000 Thermal Conductivity Thermal Conductivity (W/m-K) GKN’s TC2000 is the PM counterpart to Cast AI A380 96 commercially pure, wrought aluminum. TC2000 outperforms conventional AI 6061 180 extrusions and castings by limiting solute impurities within the alu- AI 6063 218 minum matrix. Al PM TC2000 225 Pure Aluminum 234 Qualitative Benefits Formability Manufacturability Green Design Unique, net-shape geo- High production Minimal material scrap and com- GKN engineers use modeling metries with excellent volumes with pletely recyclable material, mini- and simulation to ensure opti- tolerance control without reliable performance mizing environmental impact mized designs, meeting costly machining customer requirements LIGHTWEIGHT OURAPPLICATIONS SOLUTIONS 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 LIGHTWEIGHT OURAPPLICATIONS SOLUTIONS Planetary Reaction Carrier 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. 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 LIGHTWEIGHT OURAPPLICATIONS SOLUTIONS Forged Products GKN is in production development Bending Fatigue Strength of Aluminum forged products: 400 Tailored preform design allows for highly controllable plastic flow 350 GKN´s 2618 MMC Wrought 2618 Near-net shape, and economical process 300 eliminates subsequent working operations 250 Fatigue properties exceed wrought forged Aluminum 200 Bending Stress (+/- MPa) 150 100 1,E+03 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08 number of cycles Conventional Forged Material GKN’s Forged MMC Material LIGHTWEIGHT OURAPPLICATIONS SOLUTIONS Heat Sink GKN‘s heat sink was developed to replace die cast components for a car radio cooling application. 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 OUR SOLUTIONS Contact us here ALUMINUM TECHNOLOGY Alan Taylor Lightweight Technology [email protected] © GKN Powder Metallurgy 2018.
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