ALUMINUM

ALUMINUM TRAINING

Aluminum is a preferred choice material for reduction of weight of automotive vehicle to satisfy the stringent CO2-emission standard. Because of this up to 15 % growth is predicted till 2025 in usage of aluminum sheet. A strong competition in the Aluminum industry has now started to capture the aluminum sheet market growth by targeting production of high-quality aluminum sheet.

Light weighting by aluminum in manufacturing of non-structural parts like inner and outer panels by cold forming are already practiced by OEM’s. However, for structural parts like B-Pillar, A-pillar, C-pillar, cross beam and impact beam requires high strength aluminum alloys. But the high strength aluminum alloys are not formable at room temperature. Therefore, the process requires another forming approach.

digicon Academy offers a fully tailored training and consulting service according to your engineering needs. We provide the knowledge and which supports and empowers you to accomplish your assignment.

LEVEL 1 - BASIC TRAINING

Description

Aluminum is a preferred choice material for reduction of weight of automotive vehicle to satisfy the stringent CO2-emission standard. Because of this up to 15 % growth is predicted till 2025 in usage of aluminum sheet. A strong competition in the Aluminum industry has now started to capture the aluminum sheet market growth by targeting production of high-quality aluminum sheet.

Light weighting by aluminum in manufacturing of non-structural parts like inner and outer panels by cold forming are already practiced by OEM’s. However, for structural parts like B-Pillar, A-pillar, C-pillar, cross beam and impact beam requires high strength aluminum alloys. But the high strength aluminum alloys are not formable at room temperature. Therefore, requires another forming approach.

Audience

Engineers and technicians in the fields of production, process, tooling, material testing and QM & QS.

Prerequisites

Understanding in heat treatment and hot forming and quenching.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience hot forming and quenching in the field of aluminum and acquire a deep insight into the most efficient skills in technology.

Methods

Digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content

Hot forming and quenching of aluminum similar to press hardening of steel is a newly developed forming technology that is able to form complex shape structural parts made from high strength aluminum alloys (Fig. 1). In this processing technology, aluminum sheet is solution heat treated between 450-580°C for 0-10 min in a furnace. Thereafter it is transferred into the press. During transfer, the aluminum blanks cools. During pressing, it acquires the shape and necessary quenching. The formed and quenched parts artificially aged to T6 condition. Improvement in formability due to elevated temperature of high strength aluminum facilitates forming of complex shape parts which are not possible by cold forming. The major advantages of the hot forming and quenching process are follows:

  • The reduction of the number of individual steps means there are fewer opportunities for contamination of the metal within each process, and uncontrolled air-cooling.
  • Less energy is needed due to the reduction in the number of times the material is reheated.
  • The formability of the material is higher, due to the hardening stages being performed during or after the forming stage.
  • Spring back can also be reduced by the combination of quenching and forming stages. This, in turn, increases the geometrical tolerances of the component, allowing components to be assembled easily.
  • Distortion of the component is also limited due to the quenching stage being contained in the cold die.
  • The time of production for each component is reduced, because the component no longer has to be transferred between as many different items of process equipment. This consequently leads to financial savings.

T1: Introduction and fundamentals in Hot Forming

  • Recapitulation Process fundamentals
  • Which quality characteristics have to be fulfilled? - Critical quenching rate, Interface between tool/press/cooling, Thermal expansion, Form- ability, etc...
  • Product design, most important process parameters, tool concepts, thermal treatment

T2: Process Parameters for Tools

  • Cooling approaches, handling of problem areas
  • Segmented construction
  • Tool design
  • Failure possibilities (drawing clearance, wear, blank holder, positioning ejector, etc.)
  • Failure criteria by replica or drawing clearance measuring
  • Process control

T3: Virtual Engineering

  • From the component geometry to the tool
  • Interface definition and using software
  • How the product geometry has to be? Are there possibilities for optimization? What is not?
  • Active surface construction
  • Blank shape
  • Simulation
  • CAD (Catia)
  • Trimming

T4: Tool Materials and Coatings

  • Hot forming tool steel (mechanical and thermal properties)
  • Tool coating
  • Recent developments

T5: Practical Examples

  • Case Studies

P1: Practical Examples

  • Case Studies in the laboratory at the furnace

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 2000-L1-03

REGISTRATION

LEVEL 4 - PRE- AND POST-PROCESSES TRAINING

Description

Friction Stir Welding (FSW) is an innovative pressure welding method, which was first developed and patented in 1991 by the TWI (The Welding Institute) in the UK. Within a short period of time it has found entrance in many distinctive ranges of application, particularly, in fields of mobility. After the original patent lost its validity, an interest to use this procedure in very diverse manufacturing areas increased. The procedure distinguishes itself by the fact that it is possible to weld materials in a ductile condition without fusion. Using this technology, it is now possible to join light alloys such as Mg, Ti- and Al-alloys with a welding speed of up to 25 m/min. In the past, these materials were hardly economically weldable by fusion methods; in addition, Mg/Al and Al/Steel combinations are now producible in high quality. Moreover, the influence on the microstructure of the materials is substantially smaller compared to fusion-welded joints.

Audience

Engineering, Management and Supervisory staff from R&D, Shop floor, Quality assurance, Design, Production Planning departments in Automotive, Aviation and Ship building industry. Additionally, employees of metalworking companies who are interested in taking this welding procedure in the portfolio, e.g., by re-equipment of existing CNC machines.

Benefits

Within this crash course the most important welding parameters and influencing variables for Friction Stir Welding (FSW) are presented, considering valid standards and directives. For example, current tooling developments and their influence on the resulting microstructure in the joining area are considered. In addition, the monotonic and cyclic properties as well as the corrosion behaviour of the produced joints are targeted. Apart from the established destroying testing methods, modern non-destructive testing methods are presented. Furthermore, the current available FSW systems are described with reference to the materials and geometries to be joined. Various variants of the FSW process, for instance, hybrid FSW, Friction Stir Spot Welding and Friction Stir Processing are also covered.

Methods

Lecture, Documentation, Video clips, FSW simulation device.

Content

Theoretical units aim at creating a deep understanding of:

T1: Friction Stir Welding Basics

This process is illustrated in detail and the fundamental parameters and influencing variables are discussed thoroughly. Additionally, aspects are approached through further details, for example, appropriate tools selection, optimized work piece clamping, adequate temperature management and the assurance of a high weld quality. Key questions, for example regarding the use of position-controlled or force-controlled FSW, are answered. Dependent from the produced compounds, the most particular FSW systems are demonstrated with reference to high manufacturing speed, either a high or low metal sheet thickness or a high design flexibility of the weld joint. A FSW simulation device serves for the practical illustration of the process.

Learning objective

Based upon provided knowledge and abilities, the participants are able to understand the fundamental principles of the Friction Stir Welding process and to narrow down the choice of appropriate FSW systems composite dependent on the given conditions.

T2: Appropriate materials as well as microstructure and properties of a friction stir weld

With regard to the weldability of similar or dissimilar materials the development in FSW is advancing quite rapidly. After initially almost exclusively non-ferrous metals and light metals were joined by means of FSW, there are now the first relevant industrial applications for joining steel. Moreover, a key topic is joining of different metal alloys. With FSW it is possible to join materials, which would form non-tolerable brittle phases by using fusion welding. Connected closely to the production of the welded joint, the microstructure and mechanical properties of the welds have to be taken in account. For this purpose, the formation of the characteristic microstructure in Friction Stir welded joints is explained in detail and the interaction between the formed microstructure, the process temperature and the resulting mechanical properties is described.

In addition, monotonic properties, the resulting hardness profiles the cyclic fatigue behavior of the welded joints, and the appropriate use of high-resolution nondestructive test methods are in the foreground of this course. Furthermore, the corrosion behavior of the welds is considered. The participants are able to clarify themselves with the influences of different process parameters on the weld joint properties by programming the FSW simulation system.

Learning objective

The participants are enabled by the provided knowledge to understand and influence the weld joint properties. They become aware of the most important analysis and testing methods and can select and use the appropriate ones according to their own application needs.

T3: Current and future applications for friction stir welding as well as innovative modifications of the FSW process

Development in the technology of Friction Stir Welding is progressing extremely quick. Continual new relevant scientific papers and information have appeared with the advancement of FSW and related processes. In this unit, the most important industrial applications are shown and the crucial developers are mentioned. Additionally, a method by which information concerning current Friction Stir Weldings can be achieved, will be presented.

Moreover, important advancements such as hybrid FSW, specifically the inductively supported one and the ultrasonic-enhanced Friction Stir Welding are provided. Specialized modifications such as Friction Stir Spot Welding and Friction Stir Processing are demonstrated.

Finally, we discuss the economic efficiency of the FSW technology compared to conventional welding processes. When a Friction Stir Welding system is available on-site, we transfer the gained knowledge from the classroom and the simulation device into practice.

Learning objective

The participants acquire the ability to attain access to the required information regarding the high-dynamic developing FSW technology and to select by economic efficiency criteria the FSW process most appropriate to their specific need.

T4: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The CQI-9 Heat Treat Systems Assessment is standardized in the automotive industry, published by AIAG (Automotive Industry Action Group), the North American association of leading automobile manufacturers. The CQI-9 is supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the CQI-9 are conveyed, practical training, either directly at the furnace or in your own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and, measurement technology.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the CQI-9, optimized execution of the measurements IT, SAT, TUS.

Methods

Digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content - Theory & Practice

  • General information about the AIAG CQI-9
  • Heat Treat Systems Assessment (a catalogue of audit questions)
  • Content and application of the process tables
  • Requirements for thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 2000-L4-02

REGISTRATION

Description

The AMS2750 is standardized in the aerospace industry, published by the SAE International Group. The AMS2750 is part of the NADCAP accreditation program and supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the AMS2750 are conveyed, practical training, either directly at the furnace or in EBNER's own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and, measurement technology.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the CQI-9, optimized execution of the measurements IT, SAT, TUS.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content - Theory & Practice

  • General information about the AMS2750
  • Requirements on thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 2000-L4-03

REGISTRATION