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Development of Peeling-less Casting Billet for Forged Aluminum Suspension Arm

Article of Honda R&D Technical Review Vol.16 No.2

Summary

Change to the use of aluminum material is being promoted in order to achieve the important goal of weight reduction. However, the high cost of this material means that weight reduction by this method is currently not progressing. Here we focused on the material cost, which occupies 59% of the manufacturing cost of forged aluminum suspension arms, and developed a new continuous casting technology which does not need peeling. This is called the peeling-less casting billet. To eliminate the peeling process, it was necessary to control material segregation and surface unevenness. Therefore the material content was adjusted (adding Ca) and direct cooling during casting was used, together with adiabatic mold casting and a graphite casting mold, and those problems were overcome. This developed technology eliminated the need for peeling, and in combination with reduced costs due to equipment depreciation, it reduced the cost of forging materials approximately 20%, thus realizing a reduction in cost compared to conventional forged aluminum suspension arms.

Reference

(1) The Japan Institute of Light Metals: The Handbook of Advanced Aluminum Technology, p.334-343 (1996)
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(3) Schneider, W., Lossack, E.: Improvement of Billet Quality by Use of a Hot Top Mold with a Two Phase Lubrication, Light Metals, p. 763-768 (1987)
(4) Yamashita, T.: Characteristics of a vertical semi-continuous casting process using a heat insulating mould for a aluminum alloys, International Journal of CAST METALS RESEARCH, Vol. 9, No. 4,p. 241-247 (1996)
(5) Yamashita, T.: Solidification position and surface condition in aluminum billets produced by a vertical semi-continuous casting process using a heat insulating mold, Journal of Japan Institute of Light Metals, Vol. 46, No. 10, p. 494-499 (1996)
(6) Ushida, T., Yoshimura, O., Mashiyama, S.: The effect of small amount of beryllium on Al-Mg alloys, Journal of Japan Institute of Light Metals, Vol. 7, No. 6, p. 29-33 (1957)
(7) The Japan Institute of Light Metals: The Handbook of Advanced Aluminum Technology, p. 122 (1996)
(8) Nakae, H.: Wettability of liquid aluminum to nonmetallic materials, Journal of Japan Institute of Light Metals, Vol. 39, No. 2, p. 136-146 (1989)
(9) Nemura, A., Ohno, T., Kamado, S., Kojima, Y., Masuda, R., Oosumi, K.: Effect of remained calcium on microstructure and various properties of 6061 aluminum alloy, Journal of Japan Institute of Light Metals, Vol. 46, No. 11, p. 576-581 (1996)

Author (organization or company)

Hiroshi AKIYAMA(Honda R&D Americas, Inc.)、Yushi AMAKI(Tochigi R&D Center)、Kiyotaka TOHMA(Tochigi R&D Center)

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