meteor

Methods and technologies for validating and optimizing the resource efficiency of process networks in the manufacture of lightweight structures; sub-project: Development of a process network and virtual process chain

The use of hybrid material composites enables the potential of different materials to be optimally utilized. In particular, the combination of aluminium die casting and thermoplastic injection molding is predestined for the large-scale production of complex lightweight structures with high specific mechanical properties. Such components must be manufactured in a resource-efficient process in the future and must also be recyclable with regard to a functioning circular economy. Using the example of a hybrid gearbox and engine housing, the meteor project investigated hybrid casting as a combination of die casting, stamping and injection molding using a single machine with integrated process data acquisition (die casting machine type DSD-DuoCast) with regard to the efficient use of thermal energy. This allows process efficiency to be further increased. In addition, data acquisition serves as the basis for a virtual process chain in order to recognize disturbance in the complex process at an early stage and initiate countermeasures to prevent casting failures (Fig. 1). Furthermore, the digitalization of the coupled processes enables the precise CO₂ assessment. In addition, renewable energies in the form of a solar thermal system in combination with a heat pump and chiller were integrated into the process temperature cascade. This resulted in the development of a tuned process network for more sustainable hybrid metal-thermoplastic composite components.

Die-cast part (left), followed by: Simulation of casting defects caused by process disturbance variables. Signatures under the component illustrations: ‘a) Die-casting part’, ‘b) Entrained Air’, ‘c) Weld Lines’, ‘d) Porosities’. — Die casting part of the hybrid gearbox and motor housing and simulation of casting defects caused by process disturbance variables.

Period

01.12.2020 – 31.03.2025

Project partners

Funding

Federal Ministry for Economic Affairs and ClimateAction (BMWK): Technology Transfer Programme Lightweight Construction (TTP LB)
Funding code: 03LB2000G