금속 주조 기술의 발전: 최신 기술, 과제 및 동향 검토 – 2부: 새롭고 부활한 기술

by Dirk Lehmhus

Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Wiener Straße 12, 28359 Bremen, Germany
Metals 2024, 14(3), 334; https://doi.org/10.3390/met14030334
Submission received: 25 February 2024 / Accepted: 8 March 2024 / Published: 14 March 2024
(This article belongs to the Special Issue Advances in Metal Casting Technology)

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1. 소개

본 텍스트는 금속 주조 기술의 발전 이라는 제목의 특별호에 대해 작성된 사설의 두 번째 부분입니다 . 2022년 11월에 출판된 첫 번째 부분에는 글로벌 금속 주조 산업에 대한 개요가 포함되어 있으며 e-모빌리티, 관련 Gigacasting 기술의 출현 또는 증가하는 등 시장 및 제품의 변화를 가져온 특정 측면을 강조합니다. 주조 산업이 공정의 환경 영향을 정당화하고 최소화하도록 압력을 가하고 있습니다 [ 

1 ]. 두 번째 부분에서는 일반적인 추세 또는 이전 과제에 대한 대응으로 볼 수 있는 업계 내 기술 개발을 조사하여 다른 관점을 가정합니다. 즉, 이 텍스트는 새로운 기술과 부활한 기술에 대해 논의합니다. 그렇게 하면 완전할 수는 없지만 독자에게 추가 연구를 위한 공격 지점을 제공할 수 있습니다. 마지막 장은 특별호에 대한 기여를 다루고 있으며, 이전에 자세히 논의된 기술 분야와 관련하여 이를 맥락화합니다. 1부에서와 마찬가지로 저자의 주요 활동 분야에 따라 알루미늄 합금의 고압 다이캐스팅(HPDC)에 대한 편견이 있을 수 있으므로 독자가 이를 수용하기를 바랍니다.

Figure 1. An overview of topics covered in the present text. The graphic shows the areas of interest discussed in the previously published first part of this editorial (PART I in the diagram, see [1]) as well as those focused on in this second part. While Part I concentrated on boundary conditions, Part II is technology oriented.
Figure 2. Publication numbers sourced from Google Scholar and Scopus on semi-solid casting technologies: (a) semi-solid casting in general, (b) rheocasting and (c) thixocasting process family examples. Note that keywords had to be adapted slightly for scanning different databases.
Figure 3. Radio filter produced by means of the RSF/RheoMetalTM process. A unique feature of this product is the weight reduction of 1.6 kg facilitated by wall thicknesses as low as 0.4 mm at 40 mm height (aspect ratio 100). High conductivity low Si alloys were used, and thermal transport properties further increased by up to 20% depending on the alloy composition by means of heat treatments, as depicted in the top right diagram by means of arrows denoting the course of the latter (images provided by Comptech AB, Skillingaryd, Sweden).
Figure 4. Overview of rheocast and high-pressure die-cast aluminum and magnesium alloys in as-cast and T6 states in terms of yield strength, ultimate tensile strength and elongation at failure. The latter is represented by the size of the spheres. Data are sourced from [20,32,33,34,35,36,37,38,39,40,41,42,43].
Figure 5. An overview of principles controlling strength in compound casting. The image in the top left corner shows metallographic sections of infiltrated surface structures created via laser pulses to facilitate a micro-scale form fit. E in the image marks the worst case, poor wetting and bonding, while C denotes the middle position. More interesting are the extreme cases described in the image.
Figure 6. Sample images of parts produced by compound (a–c) and hybrid casting (d); (a,b) AlSi7Mg0.3 LPDC subsize front axle carrier frame demonstrator with integrated EN AW-6060 extrusion, general (a) and detail view (b); (c) AlSi9Cu3 HPDC e-motor housing demonstrator with integrated aluminum tubes as cooling channels, cast by ae group AG, Gerstungen, Germany; (d) aerospace secondary structure hybrid bracket combining a CFRP and an aluminum HPDC component [131] (all images by Fraunhofer IFAM).
Figure 7. The fundamental principle behind the concept of collapsible cores. Hollow microspheres are embedded in an open-porous matrix. Decoring is achieved via cold isostatic pressing. Fluid entering the open porosity of the matrix in which the microspheres are embedded exerts pressure on the latter, making them collapse. The integrity of the core is lost, and its remainders can easily be washed out [169,188].
Figure 8. (a) S-Max Pro sand printer as offered by ExOne, offering a build box of 1800 × 1000 × 700 mm (build volume 1260 L) and a build rate of up to 145 L/h, (b) examples of a printed core package for an internal combustion engine block consisting of furan-bonded components in black and hot hardened phenol-bonded components in beige (pictures kindly provided by ExOne (North Huntingdon, PA, USA); Copyright: ExOne).
Figure 9. How to enable sensors and electronic systems to survive integration in metal castings—general principles: Top left, simplify—example of a rip wire sensor [247]; top right, distribute—integrate just those components that need to be integrated [248]; bottom left, harden—use materials that can withstand the process loads [249]; bottom right, protect—shield the integrated system against thermal and/or mechanical loads [250].
Figure 10. Schematic diagram describing a concept for constant product evolution relying on monitoring of in-service loads and conditions in combination with a highly flexible manufacturing process like indirect AM, i.e., the printing of sand molds.
Figure 11. Digitalization meets the HPDC challenge. So much to measure, so much to correlate, and mere seconds left to do it in time to react on a part-by-part basis. Note that the list of parameters suggested here is indicative of the breadth of the issue only and certainly not complete.
Figure 12. The Lambda Architecture, an example of a compromise between securing accuracy and speed in data analytics by providing two interconnected analysis paths differing in timeliness and accuracy of information provided.
Figure 13. Ways of making use of data analytics—a general scheme in which almost anything, including casting processes, can take on the role of the object of observation represented by the black box.
Figure 14. Combining advanced simulation and modelling and AI or MOR techniques to realize a digital twin in casting technology covering both the design and production phase.
Figure 14. Combining advanced simulation and modelling and AI or MOR techniques to realize a digital twin in casting technology covering both the design and production phase.

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