The project "R&D and industrialization of large-size, thin-wall and complex aluminum alloy structural parts for new energy vehicles" successfully passed the evaluation of scientific and technological achievements

Precision die-casting technology integrates the preparation of high-performance alloys and the precise forming of products, and is one of the research hotspots in the field of material preparation and processing. The preparation technology of large-size and thin-walled complex aluminum alloy structural parts for new energy vehicles is a guarantee to meet the major needs of the country’s advanced equipment. It will be directly used in new energy vehicles and other fields to achieve economical, efficient and green manufacturing of high-quality complex castings, which is complicated for enterprises The independent research and development of castings provides key technical support, which plays an important role in promoting the technological upgrading of industries such as automobiles and foundries, and solving the manufacturing bottleneck of key and complex parts such as automobiles.

On March 26, 2021, the China Foundry Association hosted the conference through a video conference. It was jointly completed by Jiangsu Wencan Die-casting Co., Ltd., South China University of Technology, Xiongbang Die-casting (Nantong) Co., Ltd., Tianjin Xiongbang Die-casting Co., Ltd., and Nantong University. Scientific and Technological Achievement Evaluation Meeting of the project of “R&D and Industrialization of Aluminum Alloy Structural Parts for Large-size Thin-wall Complex New Energy Automobiles”.

The scientific and technological achievements evaluation meeting invited Professor Xiong Shoumei of Tsinghua University as the chairman of the evaluation meeting. Researcher Zhang Zhiyong, Executive Vice President and Secretary-General of China Foundry Association, Executive Vice President of China Foundry Association, Professor Fan Qi, Senior Engineer Dr. Lu Hongyuan of Buhler, and Wu Chunmiao of South China University of Technology attended the meeting.

The expert group listened to the project’s work summary report, technical summary report, test report and scientific and technological novelty report, etc., reviewed relevant materials, and after inquiries and discussions, believed that:

The project developed the key technology of high-vacuum die-casting mold system to manufacture aluminum alloy lightweight eagle-wing door inner panels, rear longitudinal beams, shock-absorbing towers and other new energy vehicle structural parts, with a minimum wall thickness of 1.3mm and a size of 1400mmX510mmX350mm.

Through microalloying treatment, the alloy composition is optimized; the high purity aluminum alloy melt is obtained by refining and standing technology; the heat treatment method of new energy automobile structural parts and the low-temperature short-term solution treatment technology have been developed to solve the problem of die casting After heat treatment "bubbling" and deformation defects, the mechanical properties reach: tensile strength 315 MPa, yield strength 204 MPa, and elongation after fracture 8.5%.

Developed an intelligent machining system for aluminum alloy structural parts of new energy vehicles, which realizes multi-angle machining and cutting through seven-axis robots, which replaces the traditional multi-process and multi-equipment processing mode. Multiple groups of robots are combined into a flexible production unit. For the first time, the multi-angle integrated processing of large, complex and thin-walled parts has been realized.

The project has obtained 9 authorized invention patents and 12 utility model patents. The products realize large-scale, complex, thin-walled integration and lightweight manufacturing, and are applied in batches to new energy sources at home and abroad, such as Daimler, Tesla, NIO, Xiaopeng, etc. In the car, the economic and social benefits are significant.

Evaluation Committee agreed to evaluate the scientific and technological achievements of the project, the project overall technical level reached domestic leading level.