Fraunhofer Institute for Production Technology IPTResearch project "DelTAM"
Everything from a single source: the megacasting production trend
An automobile consists of many parts that have to be designed, manufactured and coordinated separately using conventional processes. The production and assembly of the individual components is time-consuming and costly. In order to optimize this small-scale and complex production, the automobile industry is increasingly using so-called "megacasting" in production.
In this process, large-format aluminum components are cast in a continuous mold instead of having a separate mold for each individual part and then assembling them. This innovative die casting process used has been known in the automotive industry for many years. The scaled processes for this type of large component are known as "megacasting" or "gigacasting." Massive body components can be produced quickly and sustainably in this way. Some well-known automotive companies, such as Tesla and VW, are already using this casting process in their production.
Processing the tool shape and component with the laser
However, the increase in efficiency due to fewer assembly steps for the individual parts is offset by higher costs for post-processing, more expensive tool shapes and a challenging distribution of the molten material. Manufacturing companies need new laser technologies that are tailored to the application to carry out all processing steps of the pre- and post-process efficiently and automatically.
This is where a German-Korean consortium comes in – with the "DelTAM" research project: In the project, the research team is developing a multifunctional 6-axis laser system which can process aluminum castings automatically.
Cutting, deburring, structuring and coating – various laser technologies are used in the project as preparatory process steps. The project team structures and coats the mold with the laser to achieve optimum distribution of the molten material in the mold and a high level of wear protection for a durable die casting mold. The scientists also rely on high-power laser radiation for post-processing to remove excess aluminum material and deburr roughness on the component.
Processing of aluminum with lasers is also a particularly challenging because the material is highly reflective and has high thermal conductivity. In order to master the complexity of the large die-cast components, robots perform flexible 6-axis movements with a large distance between the laser optics and the component.
German-Korean know-how for efficient and sustainable production
While Fraunhofer IPT and Fraunhofer IAPT are developing the laser systems and processes, the Korean project partners are focusing on the automation and digitalization of the machining processes. They are optimizing the manufacturing process by using artificial intelligence (AI).
The laser system combines a wide range of laser technologies, AI-supported machine learning and 6-axis robotics in one application. It therefore enables precise processing from a distance of more than 300 mm and automatically generates processing paths adapted to the product.
Suppliers for e-mobility, in particular, benefit from the digital and real-time-capable machining concepts through speed, material savings, machining efficiency and precision: The cast components can be produced around 30 percent faster than with conventional processes. The amount of manual reworking is reduced by as much as half. Material savings of up to 10 percent lead to a further reduction in manufacturing costs. The project thus not only helps Germany and Korea reach their sustainability goals, but also saves costs in industrial production thanks to the highly flexible and automated production of large cast components.
Project Consortium
Project coordination: Yulimtech, Korea
Project partner
- DRAutotech, Korea
- EVLaser, Korea
- Korea Textile Machinery Convergence Research Institute, Korea
- Daegu Mechatronics & Materials Institute, Korea
- Korea Automotive Technology Institute, Korea
- Fraunhofer-Institut für Produktionstechnologie IPT, Germany
- The Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT, Germany
Funding
Sponsor: Ministry of Trade, Industry and Energy of South Korea (MOTIE)
Support program: Joint R&D Project of the Global Industrial Technology Cooperation Center (GITCC)
Funding code: P246800137
Project sponsor: Korea Institute for Advancement of Technology (KIAT)