2010 China international conference for investment & development of diecasting industry

Current status and technology trend

of
Korea Diecasting Industry

Ok-soo Kim, Ph.D

Korea Institute of Industrial Technology (KITECH)
 Castings production in the world

100000

World castings production has been increased

90000
by 36.7% from 2001 to 2008.
80000 China occupied 35.8% of world production in 2008,
ranking 1st in the world.
Castings production (x 103 Mt)

China
70000 USA Korea produced approx. 2.0million ton in 2008,
Russia occupying 2.2% of world production.
60000
Japan
cast steel copper 1.2% etc.
50000
India pipe &
7.4% etc 0.5% 9%
Germany fitting
ship 3%
40000 Brazil building
Italy 4%
30000 France
aluminum cast iron
Korea 24.3% 2,065,900 48.8%
20000 machinery 2,065,900
(Mt) 16% (Mt)
10000 ductile
construction automotive
cast iron 59%
0 17.8% 9%
2001 2003 2005 2008 (yr)

Castings production in the world Industry segment of casting material and its use
in Korea [2008]

2
Fuel efficiency & CO2 emission with weight of vehicles

3
Competition of Korean automobile in fuel efficiency & CO2 emission

• Better than industrial average in fuel efficiency and CO2 emission in 2007
• Planning to achieve CAFE 36.3mpg in 2015 and Europe129g/km 2012

North America Europe

▷ America CAFE Fuel efficiency (’07) ▷ Europe CO2 emission(’07)

[mpg] [g/km]
better
better 177 182
29.0 29.7 29.5 161 163 166
27.6 Average : 26.8 Average : 158
146 151 151 153 156
25.2 141
25.1 24.2

HMC Toyota Honda Nissan GM Ford Crysler

2007 2010 2012 2015

Goal of Fuel
efficiency present 10% up 20% up 25% up

* Source : HMC(2010)
4
Current and forecast of Al & Mg use in a vehicle in Korea

(Kg)

Al & Mg use in Korean automotive

400 45 industry has been gradually increased.
350
355
Especially, in an eco-friendly vehicles
300 such as HV, FCV& EV, Al more 3times
250 than in a conventional vehicle is expected
200 to be used.
150 45 Diecasting production and related
12 Mg
100 3 110
98 technology will be continuously increased
80 Al
50 and developed with the trend of
0 lightweight of a vehicle.
1996 2009 2020(f) (yr)
Internal combustion eng. HV, FCV

Vehicle weight Reduction : 2010-10% , 2020-16% reduction

(compared to 1996)

* Source : HMC(2010)
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 Outline of current status of Korea Diecasting Industry

250,000
Annual total production : 75,000(’96)→235,000(’08)
(Diecasting production, Mt)

Demand for automotive part has been increased

200,000
over the past 10yrs. (75.8→78.0%)
Mg
150,000
Zn other
components other
Al components
12.9%
100,000
9.8%
electric & electric &
electronic electronic
11.3% 12.2%
50,000
Automotive Automotive
75.8% 78.0%
0
1996 2005 2008 (yr)

Diecasting production in Korea 1996 2008

Industry segment for use in Korea

6
 Outline of current status of Korea Diecasting Industry

Diecasters : approx. 600 companies(major : 100 companies)

Installed diecasting m/c : about 2,900 machines (as of 2009)

[Brief intro. of Korea diecasting

강원권
주요업체 industry history ]
-깁스코리아
서울 경기권 • The mid-1960s: First introduced
주요업체
-삼기기공㈜,이노캐스트 • The late-1970s : Vitalized with the
충청권
-대광DC, 우성DC
-원태DC, 스타메탈 주요업체 beginning of domestic automobile industry
-대명정밀,서천금속 -코넥
-대진DC, 신광DC -GM A&T 영남권 • The 1980s ~2000s: Rapidly progressed
-동성DC, 씨멕스 -그로웰메탈
-보령DC, 영DC -매그너PT 주요업체 with the growth of automobile industry
-㈜보성,영성DC -서경TSC -현대(자)경합금주조부, 동남정밀
-보원DC,일신DC -해광 등 -대우정밀, 대림자동차, 삼광정밀 (special diecasting processes and
-동양DC, 일오DC -뉴텍, 금오공업,삼영M/T, NSC
-삼오정밀, 제일금속 -㈜모토닉,평화기공, ㈜동양,KH바텍 materials have been developed to meet
-삼창공업, 중앙금속 -㈜삼정, 세광정밀, 청암금속
-코다코, 한라DC
호남권 -대산금속, 부성정밀,경북크랑크
-두원중공업, 다원금속, 보고Mg
the quality of automotive parts)
-한진DC, 현대테크 주요업체 -동양산업,대보공업, 영강금속
-신창정기,삼원금속 -세명테크 -캐스탑, Al테크,파란테크, 일흥금속
• The early-2000s : CAE tech. in mold
-인지AMT, 원텍 -㈜대용
-다우하이텍,임동 등 -진보산업,영진정밀,금영정공
-영신정밀 등 -KED산업, 한미AMD, 세아메카닉스 designing and Mg based automotive parts
-국원공업, 동일DCM, 삼성정기
-삼원금속, 보원산업, 대주산업 have begun to be used and developed in
-삼우정공, 신성전자, SH산업
-세일사, 서화,다원테크 등 earnest

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Cooperative for Korean diecasting industry

Cooperative purchasing
- raw material and used related machines

Publishing

Main activities
- http: www. diecasting.or.kr - News letter and technical journal

- Established in 1995 Education & Training

- by domestic or overseas experts
- Membership and members - periodical international symposium
: domestic diecasting and its related companies - Joint benchmarking for leading companies
: approx. 120 companies joined Sales promotion for members
-supporting joint marketing and overseas exposition facilities

Supporting member’s management

-Joint arrange for overseas workers
-Mutual visiting and tech. exchange for members
- Political suggestion to the government

8
 Recent motivation of diecasting technology in Korea

Very closely correlated with the trend of Korean automotive industry.

Major R&D activities

Higher reliability , Lighter , more integrated In Korea diecasting industry
in automotive industry ▷ Development of new advanced alloy
( incl. High stiffness, weldable Al and high temp. Mg alloy)
▷ Increased fuel efficiency ▷ Technology of optimized mold design
▷ Lower manufacturing & shipping cost (incl. CAE tech. in designing gating system)
▷ Lower emissions ▷ Special forming process
▷ Increased vehicle performance - Vacuum diecasting
• Increased acceleration - Local squeezing diecasting
• Shorter stopping distance - Hot sleeve diecasting
• Better steering - High Vacuum diecasting
▷ Improved durability - High speed injection diecasting
- Semi-solid diecasting
▷Digital production management & clean production

9
Development trend of components by diecasting process in Korea

Mg Cowl cross member

Mg steering wheel Mg seat frame

Mg engine block
Auto valve body by vacuum diecasting Auto transmission case

Ladder frame AL Car body frame

Clutch housing

AL engine block by HPDC

Engine oil pan

Engine oil pan CAE tech Timing chain case

~1990 1995 2000 2005 2010~

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Key focuses of recent R &D activities in diecasting process

Process Key focuses

Melting High purity of the melt (elimination of foreign material, inclusion etc.),

Use of High temp. adhesive lubricant , fast spraying

Spraying
(Oil-based lubricant, High temp. adhesive water-based lubricant, serviceability in high temp.)

Hot sleeve ( Oil or electric heating, ceramic)

Melt Pouring Increased holding ability of melt temp. & high filling rate
Prevention of oxidation of the melt

Appropriate filling speed, Use of lubricant which has high lubricity

Melt Injection
Sufficient gas venting (Parting line, Sleeve, Core Pin, Ejecting Pin, massive gas venting, vacuum etc.)

Prevention of high temp. crack ( Uniform of wall thickness, Setup of Radius )

Solidification
Prevention of shrink crack (Shortening of chill time, Setup of Radius)

Ejection Prevention of deformation and scratch

& Take-out (Parallel and fast ejection)

Full automation in deburring process

deburring
Prevention of punching mark

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Key processes of automotive components by HPDC in Korea

Mold Design
Product design
▷ optimal casting design
▷ design considerations
- Gating(filling, venting) system
- performance
- high productivity
- strength & stiffness
- prevention of deformation
+ + - Die temp. control unit
(Cooling & Heating channel )
- formability
Oil Filter - CAE analysis
- FEM analysis
Engine Oil Pan Bed Plate Bracket
▷ Highly precise clearance
in core, pins & Prevention of
deformation of product
Material
▷ selection of optimal material
Process design
- Mechanical, thermal property
▷ optimal casting process
- castability
- High vacuum
- High speed injection
Engine Lower Block
- Partial squeezing
- Hot sleeve
▷ Proper die lubricant

12
Product design by FEM analysis for diecasting process

- Rib shifted to improve stiffness

- increased draft angle (min 2 ˚)

- wall thickness in hemming part : 2.0t

- wall thickness in inner part : 3.0t

- Ribs to increase stiffness

Integrated Door Inner

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Optimized casting design by CAE tech.

Simulation result
Casting design
Filling velocity Temp.distribution in flling

product
gate

runner

Above 30m/s in the early length of the runner Above 620℃ of the melt temp.
→ needed to adjust the geometry or wall maintained until the final
biscuit
thickness filling was finished

Integrated Door Inner

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Optimization of casting design by CAE tech. (filling simulation)

50%, 2047ms 65%, 2169ms 80%, 2184ms 95%, 2198ms

50%, 2047ms 60%, 2135ms 80%, 2184ms 95%, 2198ms

Casting design)
55%, 2091ms 65%, 2169ms 80%, 2184ms 95%, 2198ms

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Optimization of casting design by CAE tech. (solidification simulation)

① ②

8sec 18sec
① ②

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 Development of advanced simulation module

For the molten metal behavior in vacuum condition in mold cavity By Anycasting.co

(a)

(b)

No Vacuum
650mmHg 500mmHg 250mmHg 60mmHg
(760mmHg)

Fig. 4. Analytic (a) and experimental (b) molten metal behaviors with the variation of vacuum degree in
cavity (before high velocity filling, Table 2. (b))

17
Characteristics of various diecasting processes

Large scale
gas porosity shrinkage Filling defect Chill layer
Thin-walled casting

High vacuum diecasting ○ △ ○ ○ ○

PF diecasting ○ △ ○ X △
Laminar filling diecasting ○ ○ △ X X

Vacuum diecasting △ △ ○ X ○

Semi-solid diecasting ○ ○ △ △ △

Large

High vacuum diecasting

Product Size

Conventional
Diecasting

low pressure, squeeze

gravity casting diecasting

Small
Low Quality High

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High Vacuum Diecasting process

▪ Conventional Diecasting
- Good Productivity
- Poor Internal Quality
(Gas porosity → Poor weldability,
low mechanical properties

▪ Vacuum Diecasting
-Vacuum deg. : 200 mmHg ↓
- Reduced gas porosity
- Poor Weldability and T6 heat treatment

▪ High Vacuum Diecasting (HVD)

- Vacuum deg. : 38 mmHg ↓
- Remarkably reduced gas porosity
→ Good Weldability / Heat treatment
→ Good mechanical properties conventional Vacuum
HVD Process
Diecasting Diecasting

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 Key points of process design in High Vacuum Diecasting

▪ Massive vent Design

→ melt’s filling & solidification behavior
→ selection of chill metal (BeCu etc.)
→ optimal geometry condition ▪ Design for optimal venting capability
→ Optimal venting capacity and time, condition
for controlling vacuum degree

▪ Design for optimal injection system

▪ Optimized Design for High Vacuum Diecasting → Tech. of clearance of injection tip & sleeve and cooling capability
→ Tech. of highly precise sealing in ejecting pins & parting line → Set-up of optimal condition for vacuum injection (time ,position, etc.)
(Seal : si-based, VITON-based + Teflon Coated material) → Special injection tip for high sealing

20
Local Squeeze Diecasting

by Conventional diecasting

by Local squeeze diecasting

21
High Speed Injection Diecasting for thin walled parts

▶ Injection profile (conventional) ▶ Injection profile (High speed)

Liquid Pressure
Pressue

Liquid Liquid Liquid

Temp. Temp.
/ /
solid solid
Solid
Velocity
Velocity Solid

Time Time

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 Hot sleeve Diecasting

Temperature profile during diecasting process with the variation of temperature on shot sleeve

T1

Temperature (℃)
Fig. Schematic drawing of experimental setup

T2 T3

Temperature (℃)
Temperature (℃)

→ Diecasting process →

23
 Hot sleeve Diecasting

Chill layers in the cross-sectioned biscuits with the variation of temperature on shot sleeve

24
Temperature control in Mg HPDC

Shot Sleeve / Plunger

W mob W fi x

1 2 1 2
3 4 3 4
5 6 5 6
1 2 1 2
3 4 3 4
5 6 5 6

GEB 13410

Hydraulics Mold Cavity / Holder / Slides / Cores

[2009 Intl’ diecasting symposium, Regloplas]

25
 Development of H-NCM - Comparison of Rheocasting Processes
Mechanism – increase the heterogeneous nucleation
sites on the inner wall by stirring

◆ Effect of stirring during nucleation Non-stirring

(1) no initial dendritic solidification on the vessel wall during
nucleation → no latent heat of freezing → fast cooling
(2) uniform temperature and solute concentration fields
→ stability S/L interface → globular
(3) increase in number of nuclei & survival

◆ Consequently,
(1) fine and uniform globular microstructure
(2) short cycle time
(3) improve rheological behavior
200μm
(4) efficiency and accuracy of process control

Large
processing
window H-NCM

Cont.
Growth
Box Nucleation Diecasting
by H-NCM
Time(s) 200μm
[Source: ]
26
Nano-Casting Method
Case (3): 0.05~0.3 m/s (shot speed) using a conventional diecasting machine

100μm
100μm

Gravity-casting Nano-casting

Microstructure Observation

Diecast machine： 800DC, Pouring weight: 2.9 kg

[Source: ]
27
Mg- High Pressure Diecasting

Characteristics of Mg - High Pressure Diecasting

▶ ▪ Light Weight
▪ NVH improvement
▪ Mold life increment
▪ Good productivity

▶▷ ▪ Design of the parts suitable for magnesium

 evenly designed wall thickness
▪ It requires a compact filling front
(minimum swirling)
 optimization of the gate with fill test.
▪ Optimum temperature control of the die
 very even die temperatures are necessary
▪ Spraying technology
▪(Very) fast die filling

28
Mg New Applications in Korean vehicle

29
Digital Production Management in Korea diecasting industry

POP SYSTEM LAYOUT

☞ * 공장단위별 DATA GATHERING PC 각 1대씩 배치되어 현장 DATA 실시갂 수집, 이를 POP SERVER에 전송
* M/C에서 GATHERING PC로 DATA 전송은 무선 통신망을 이용
* POP SERVER에서 ERP 연계하여 작업지시 및 실생산수량을 ERP에서도 공유 가능

ERP서버 POP서버

MS
SQL

Data Gathering PC Data Gathering PC

DDE I/O Server DDE I/O Server

실시갂 정보 수집 실시갂 정보 수집

1공장(M/C 16대) 2공장(M/C 10대)

30
Clean Production in Korea diecasting industy

Natural venting of mist and VOCs, Easy work with pneumatic parallel movement, Easy casting take-out and mold maintenance

31
 Thank you
for your attention !

32