Hybride Fertigungsprozessketten Gießen-Additiv. Wie Aluminiumdruckguss gewinnbringend mit der additiven Fertigung kombiniert werden kann
Hybrid production process chains Casting-Additive. How aluminum die casting can be usefully enhanced with additive manufacturing
Through derivatization and integration of new technologies, the number of variants in automotive industry is constantly increasing. This is where die casting, the widely used tool-bound large-scale production process, comes up against its economic and technical limits. On the other hand, tool-free additive manufacturing processes are trying to break into the automotive industry despite the high cost pressure. The advantages can be combined and disadvantages reduced by combinations of these two processes to form hybrid production process chains Casting-Additive in order to counter the trends in the automotive industry. This is being investigated as part of the joint research project "CastAutoGen" of Audi AG, Oerlikon AM Europe GmbH, EDAG Engineering GmbH, BOHAI TRIMET Automotive Holding GmbH, ZF Friedrichshafen AG and the Fraunhofer institutes IWU and IWS. In this project, combinations of casting with laser beam melting (LBM) and laser deposition welding (LMD) are developed. The aim is to create variants and functionalize die-cast components through new production approaches with reduced tool variants and costs. In the future, this should enable the manufacture of highly individual components based on basic component designs ("mass customization"). The implementation is based on two demonstrators from the automotive industry. In the auxiliary bracket, laser-melted inserts from selected material classes (aluminium, copper, steel) are developed for the die-casting process, which enable additional functions in the component (e.g. heat exchanger, reinforcement) and integrate specific adapter geometries for further attachments. Using the example of an engine mount, reinforcements, geometrically flexible joining elements and individual geometric areas for use in high-performance vehicles are added on a large-series die-cast component with the help of laser deposition welding. Special attention is paid to the material-locking connection of the differently manufactured areas.