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2002 News Release
July 24 
July 24, 2002
DEVELOPMENT OF NEW ALUMINUM ALLOY CASTING METHODS
Serialization of Casting Components for Vehicle Suspension Parts
Tokyo, Japan, July 24, 2002-Hitachi Metals, Ltd., announced today that it has successfully developed practical applications for new aluminum alloy casting techniques, which make possible the serialization of casting materials for suspension system components from cast iron to aluminum alloys.
1. Development
Mindful of the need to protect the global environment and save resources, the automaking industry is rapidly developing vehicles that consume less fuel. To realize this aim, engines have to be made more efficient and vehicles lighter. In particular, fuel efficiency is substantially improved if the unsprung weight of the suspension and other parts can be lowered.As materials for parts such as the suspension arm and knuckle/housing, Hitachi Metals has already developed the highly tenacious ductile iron HNM™ the thin, highly tenacious ductile iron NMSTM, and enhanced-surface ductile iron HB-NM. The Company has also developed the semisolid die-cast method (SSM) for aluminum.
Hitachi Metals' new aluminum alloy casting technologies-one an improvement of the proprietary HIVAC method and the other the new Feed and Heat Management (FAHM) method-are responses to diversifying demand for lighter vehicles.
Hitachi Metals has serialized casting materials for suspension parts from HNMTM to aluminum alloys. Use of optimum components and techniques with a wide variety of applications has enabled Hitachi Metals to achieve weight reductions of 5% to 60% compared with conventional general ductile iron.
2. Applying the HIVAC Method to Suspension Parts
Hitachi Metals has greatly improved the proprietary Hitachi Vacuum Die-Casting (HIVAC) process used for aluminum alloy components for engine parts so that it can also be applied to suspension parts. In addition to developing high-strength, high-tenacity die-cast materials, Hitachi Metals has reduced the volumes of gas that is mixed in during casting to one-fifth the level of the conventional HIVAC method. The advantages of this new technology are as follows:| 1) | High casting strength and tenacity | |
| 2) | Applications at a thinness of 1mm are possible | |
| 3) | As gas content is low, welding is possible |
3. The FAHM Method
The FAHM method is the result of continuous improvement of die-casting technologies for aluminum alloys. Using Computer-Aided Engineering (CAE), the method improves die-design and development technologies. By combining optimized forming technologies using molten metal flows and solid simulation at the product design stage with melt purification and other technologies, it is possible to achieve stable mechanical properties. The advantages of this new technology are as follows:- The microscopic metallographic structure and prevention of internal defects ensure a high-strength, high-tenacity product.
- Applications at a thinness of 2.5mm are possible.
- Casting of hollow items is possible.
- Superior in cost performance to the molten metal forging method
4. Sales Targets
Fiscal 2002: ¥3 billion; Fiscal 2005: ¥5 billion5. Manufacturing and Marketing
Manufacturing: Automotive Components Company: Kyushu Works, Moka Works, Kumagaya Light Alloys PlantMarketing: Automotive Components Company
Inquiries:
| Media: | Public Relations Office Officer in charge: Kobayashi Tel:+81-3-5765-4079 |
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| Products: | Automotive Components
Company Officer in charge: Okazaki Tel: +81-3-5765-4239 |
