LKR Leichtmetallkompetenzzentrum Ranshofen

Fully automated test facility on an industrial scale for the development of complex die-casting components made of aluminium and magnesium materials as well as for process and material development

LKR is expanding its industrial related casting research portfolio by the start-up of a new cold chamber high-pressure die casting machine (FRECH K-DAK1100 type). In order to work under quasi-production conditions the fully automated casting unit from FRECH is equipped with all necessary peripheral devices:

• Hindenlang KLEM 1200 crucible furnace with a capacity of max. 1.000 kg
• Meltec AVDL linear dosage system with a capacity of 1 - 5 kg and 5 - 20 kg
• Wollin spray device
• Robamat mould tempering units for heating and cooling
• KUKA cast part-removal and -insert robot

The cold chamber die casting machine with a horizontal casting unit will be applied for casting of aluminium and magnesium parts up to 20 kg in industrial scaled research projects. At a clamping force of 12.000 kN and at a mould height of max 1.2000 mm it will be possible to cast vehicle structural cast parts. In 2019 the plant was extended by a Magnesium melting and dosing equipment.

LKRs research work is actually focused on Aluminium and Magnesium alloy development and on the process development respective process optimization. New mould temperature control techniques like near-surface cooling, enabled by additive manufactured mould inserts, temperature control units and by innovative mould spraying techniques will be investigated. This research will lead to improved mould lifetime and shorter cycle time.

From the melt to the drawn wire

Semi industrial and experimental direct chill casting machine for horizontal and vertical continuous casting of Aluminium and Magnesium alloys with real time control unit

After a one-year development phase, the new horizontal continuous casting line was commissioned at the LKR Leichtmetallkompetenzzentrum Ranshofen in 2017. The tailor-made plant technology was developed by scientists of the LKR together with partner companies as part of the project BAWeRIA (Bavarian-Austrian advanced Welding Wire Research and Innovation Action). The new HSG makes it possible to produce semi-finished products from special alloys on a semi-industrial scale, including those for the production of welding wire, with a short delivery time and at low costs. The current research focus is on further developing the process technology in order to produce customer-specific formats in top quality suitable for direct further processing without intermediate steps - from semi-finished product to finished product. The objective is e.g. to be able to integrate and dynamically operate all core processes from the melt to the finished, drawn wire. In addition to the modern in-house vertical continuous casting technology for magnesium and aluminum alloys, the horizontal continuous casting line rounds off the experimental portfolio of the LKR.

https://www.ait.ac.at/en/research-topics/casting-technologies/continuous-casting/

Everything under one roof: the smart Wire Production Route at LKR

In the newly established Additive Manufacturing Laboratory at the LKR, complex 3D components are manufactured using the modern WAAM (wire+arc additive manufacturing) process. The LKR scientists have been researching the necessary WAAM-compatible welding wires made of aluminum and magnesium materials for several years. These special wires are developed, pressed and wound in the company's own smart wire production route. A welding robot uses these wires to produce a component by superimposing the welding wire in several layers on top of each other. In the AM-Laboratory, complex 3D components can be assembled using material-specific process control, a multi-axis robotic system and state-of-the-art torch technologies.

"The LKR is a pioneer in the research and further development of the WAAM process as a future key technology for industry. The advantage lies in the fact that complicated geometries can be realized with reduced material input and little waste," says DI Martin Schnall, WAAM expert at LKR. LKR scientists pursue a holistic research and development approach in order to improve the wire materials used process-specifically and to achieve increased mechanical properties for aluminium and magnesium wires. The development process covers the entire value chain. Starting with alloy definition and production, through wire production with special alloys, welding and WAAM process adaptations, to final prototypes and their material and mechanical characterization.

Dr. Stephan Ucsnik, Thematic Coordinator Material Based Design adds: "In addition to the experimental welding and WAAM developments, the related topics FEM-based material and process simulation, online monitoring, data management, CAD-CAM interface and inline process control are researched at the LKR.

The LKR Leichtmetallkompetenzzentrum Ranshofen focuses on the development of high-quality light metal alloys for future industrial applications. In a research project at LKR Leichtmetallkompetenzzentrum Ranshofen, scientists have succeeded in developing flame-retardant magnesium alloys which self-extinguish in the event of a fire. This improved fire-resistance was achieved through the selective addition of alloy elements which significantly stabilise the materials oxidation behaviour when subject to fire: We are primarily investigating calcium alloys because calcium is cost-efficient and readily available. We can also add extra rare earth elements into the alloy to positively influence other material properties and to optimise the alloy for a particular application, explains AIT Scientist Stefan Gneiger. Magnesium is in great demand in lightweight construction as a means of reducing weight and emissions in the mobility sector.

https://www.ait.ac.at/en/research-topics/casting-technologies/projects/flame-resistant-magnesium-alloys/

Modern high-performance materials permanently open new, increasingly demanding fields of application which require a comprehensive knowledge of the materials and their production processes. Using modern methods, the LKR Leichtmetallkompetenzzentrum is accredited according EN 17025 and offers a complete spectrum of microstructure, material and process characterization procedures.

Analysis methods:

Materialography

• Analysis of complex compound materials
• Charakterisation of topology

Spektrometry

• Al- and Mg-base alloys

Dilatometry

• Miniaturised sample geometries
• Simulation and charakterisation of forming processes and heat treatment processes

Analysis of notch rupture

• Fully instrumented notch impact test

Deformation analysis

• Fully instrumented deformation analysis of sheet materials
• Nakajima- and cupping test

Test methods:

Mechanical materials testing

• Tensile and pressure test from -170°C up to 300°C
• Brinell hardness testing

Fatigue test

• of material samples and components

Metallography

• Characterisation of grindings
• Grain size measurement
• Analysis of microhardness

DSC

• Phase formation and phase transformation
• Characterization of heat treatment parameters

https://www.ait.ac.at/en/labs/material-testing-and-characterisation/