Soundcast objectives and targets

To develop the know-how for producing sound and weldable high performance aluminium components by a low cost vacuum assisted HPDC process (VPDC), taking the whole fabrication process into account.

A technology package for the whole process

The project delivers one package covering numerical simulation, die design, melt and heat treatment, die lubrication, the HPDC process itself, the vacuum system, the welding process and the quality control system.

New and recycled alloys

The team develops secondary alloys with high mechanical properties, optimised by micro-additions of alloying elements and by economical, environmentally friendly heat treatments. Alongside this comes the formulation of recycled aluminium alloys and a methodology for melt and heat treatment of the new alloys.

Quality control

A quality control system is built to guarantee the mechanical properties of VPDC components. It rests on two new pieces of software: one for melt quality control based on thermal analysis, and one for process control based on statistical analysis.

Welding

A new welding process is developed for VPDC components made from the new alloys, together with a die lubrication that suits welding or heat treatment. The project also works on a laser welding process at reduced pressure.