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P owder L ight M etals High Performance Aluminium Fields of Operation Development Production Marketing PM High Performance- Aluminium (micro-crystalline and nano-crystalline) Semi’s Blanks Components Powder Light M etals High Performance Aluminium Co-operations for Development and Production Powder Light Metals co-operates with chosen partners, universities and institutes worldwide on development and production optimisation ECKA Granules FCT Systeme GmbH, Rauenstein Morphic Technology, Sweden Technical University of Berlin IFAM Dresden University of Stuttgart University of Lueven, Belgium Aluminiumwerke Unna Otto Fuchs Powder feedstock FAST direct compaction Adiabatic metal forming Extrusion optimisation Alloy and process development Metal forming Alloy and process development Extrusion Indirect extrusion Powder Light M etals High Performance Aluminium Sales and Marketing Organisation Powder Light Metals is active worldwide in sales and marketing Burger Consulting GmbH Germany Stadele Consulting and Engineering Italy and Germany Aluminium Solutions in association with Aluminium Special Products United Kingdom and USA Powder Light M etals High Performance Aluminium Requirements for high Performance Aluminium Alloys Highest strength in combination with good fracture toughness High strength for medium temperatures up to 400 OC High Specific Stiffness Excellent wear resistance Extremely low co-efficient of thermal expansion (CTE) Good thermal and/or electrical conductivity Superior corrosion resistance in different environments Good formability using standard equipment Good machinability Ease of recycling Powder Light M etals High Performance Aluminium Why Powder Metallurgy/Rapid Solidification? Development and production of new micro-crystalline or nanocrystalline high performance alloys with improved properties by: - increased alloy content - additional alloying elements - superior homogeneous microstructure - nano-crystalline or quasi-crystalline microstructure Improved hardening mechanisms from traditional precipitation hardening to dispersion strengthening or a combination of both. Conversion of cast alloys to wrought alloys (AlSi…) Tailor made alloys for specific applications (design for application) Powder Light M etals High Performance Aluminium Processes for Powder / Feedstock Production liquid gas atomization melt spinning gas atomization melt extraction spray compaction centrifugal atomization 7 10 K/s direct chill casting increasing cooling rates 10 K/s Powder Light M etals High Performance Aluminium Principle “Melt Spinning” Powder Light M etals High Performance Aluminium Powder Light M etals High Performance Aluminium Powder Light M etals High Performance Aluminium Pistons for IC Engines Light-weight forged piston for petrol Requirements engines -High Temperature strength -Fatigue strength (high temperatures) - Thermal Shock resistance - Resistance against cavitation erosion - Wear Resistance Solution RS Al Alloys by atomization or melt spinning AlMg20Si10-TM (e.g. AlSi20–TM, Local reinforcement (e.g. friction welding) of cast pistons for DI- Diesel- Engines Powder Light M etals High Performance Aluminium Lightweight cylinder liners Powder Light M etals High Performance Aluminium Light-weight materials for valve train components Powder Light M etals High Performance Aluminium Lightweight oil pump gears Powder Light M etals High Performance Aluminium Al- B4C- Plates (20 wt.-% B4C) Application- Neutron Absorption in Nuclear Waste Containers ManufacturingPowder Blending CIP HIP Rolling Plates Powder Light M etals High Performance Aluminium Al Ni8 Mn2 Cu …… substitution of AA2618 for highly stressed components - Higher service temperatures at the same strength level - Higher strength level at the same service temperature Powder Light M etals High Performance Aluminium High Strength Aluminium Screws Requirements: - high strength at room temperature (750 – 800 MPa) - strength at 150°C – 200°C (min. 450 MPa and 350 MPa, respectively) - good relaxation properties - creep resistance - corrosion resistance - low friction coefficient - good coating properties Applications: - Cylinder head - Gear boxes - Satellites - Split rims - Connecting rods - Bearing caps - others M etals Light Powder High Performance Aluminium Controlled linear thermal expansion AlSi Alloys Properties: - controlled thermal expansion: 7 – 24 ppm CTE ( *10-6K-1) 30 - low densities: 2,4 – 2,7g/cm³ - high thermal conductivity: 120 – 180 W/mK - electrical conductivity: < 10-6 ohm x cm - excellent thermal stability up to 500°C - high specific stiffness 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 Si - content (wt.-%) Replacements for: - Copper Molybdenum (Cu-Mo / Mo-Cu) - Copper Tungsten (Cu-W / W-Cu) - Aluminium Silicon Carbide (Al-SiC) - Kovar Applications : - RF and Microwave Packages - Electro-Optical Housings - Heat Sinks and Heat Spreaders - General Electronic Packages - Waveguides and Microwave Filter Components - Carrier Plates for HF Circuits - Components for Inertial Systems PM-SiAl40; 500x Powder Light M etals High Performance Aluminium Spool Valves made from PM-AlSi17FeCuMgZr (alternative to AlMgSi0,5 with Hard-Coating) Properties: - superior wear resistance without any additional coatings - excellent machinability (short chips) - non magnetic - easy burr removing Applications : - Control Unit for Automatic Transmission - Pressure Control Valve in Oil-Pumps - Center Screw in Variable Valve Timing System (VVT)