Automotive on Kereso Barat

Aluminium die casting

Aluminium is the choice metal for making light weight parts of vehicles, aerospace and transport industries. Casting of liquid aluminium alloys into metal moulds utilizing systems like gravity, low pressure and high pressure die casting is an economical way of making difficult shapes which need minimum machining. Australia’s auto industry supports a large local die casting business, manufacturing parts that include cylinders, pistons and engine sumps etc.

Rising demand in world auto market for aluminium die cast parts is producing great opportunity and challenge for Australian business which wants to emerge as a global player. By setting partnerships between Nissan and Ford, CAST has developed and produced new and latest technology that has been benefiting our partner’s products. In turn these skills have created IP that is poised on the verge of commercialization.

To increase production of high pressure die casting by lessening its time cycle by 30%. The cycle time has been reduced by more than 20% on certain parts at two industry partner plants. The project involves identifying places where cycle time may be reduced, and doing it practically to prove the findings of research. This made it essential to involve shop floor staff to implement the changes needed in systems. These trails are generally in variation with day to day production and due to true co-operation of shop floor staff it become possible to achieve targets.

The third year of project has seen the true spirit of co-operation between researches and industrial partners in which latest research results got through simulated trails have been done practically on shop floor with help and support of Ford and Nissan staff. The changes once tested during trials have been incorporated in production systems giving benefits of reduced costs by reducing time of each part manufactured. An example of reduced time achieved is at Nissan on a gearbox side cover made in twin cavity die has given successful results after many months; from an initial cycle time of 75 seconds down to 60 seconds. While research at Ford on a changer housing casting, has been successfully implemented by lessening cycle time from 90 seconds to 74 seconds.

In future the reduction of time cycle will be tried for other parts as well.

Automatic fault detection in aluminium die casting:

This involves developing a system to detect surface and sub surface defects.

A fully automatic fault detecting machine named CAST vision has been produced and a prototype process is in place for extended in-plant on-line trials. This is the third year of this project and it is giving good results. The result of algorithm which was designed and developed in 2nd year has been put to test now. By prototyping the CAST team had designed and developed a working system CAST vision. This can discriminate between good and defective parts.

The prototype system has capacity to detect blocked holes on any of holes on this complex casting. Offline processes have also been readied which will detect hot tears and cold shuts on Ford’s structural sump casting.

Work at Nissan on their pump cover casting has led to a CAST vision type process for in-line fault detection. The process can take images and find certain types of defects on the surface part. This project has shown that advances in mechanical vision applied for finding faults of aluminium castings can be converted from project stage to a working prototype successfully. The next stage is take concepts from single stage to multistage processes capable to handle more complex shapes and surfaces. This result will become a strong contender for future commercialization.

To buy or not to buy — that is the question on many peoples mind these days when it comes to purchasing a new car. With gas prices being as astronomically high as they are, a great many people are looking at hybrid cars to solve the “grump at the pump syndrome.” Hybrid cars may be money-saving for drivers and a grand “pollution-solution;” however, there are things you may not know that might influence your choice. The following represents examples you should seriously consider as some of the “bad news” about hybrid cars:

1. Hybrid cars incorporate new technology. When technology is new and minimally tested, there always exists the “reboot” scenario. As an example, until all the glitches are resolved, a hybrid car “vehicular reboot” in the middle of rush hour traffic could be a nightmare. Another hard-to-imagine example is being alone and losing power late at night;

2. Hybrid cars are lightweight. Hybrid cars have to accommodate large battery packs making the lighter materials necessary. There may never be “just a fender-bender” in a hybrid car. You should consider that what was once just a minor collision in an ordinary car may be much worse in a hybrid car;

3. Hybrid cars are small. If you have a long Christmas list and wait until the last minute, don’t try to take the kids with you in a hybrid car to the mall. Hybrid cars, at the present time, have very limited cargo and seating space;

4. Hybrid cars are too quiet. Taking a silently golden ride down a country road in your hybrid car sounds lovely. BUT – hybrid cars run so silently that a child getting ready to dash across that county road may not hear you coming. While driving any vehicle demands great attention, it is even more important in the quiet hybrid car for the safety of all pedestrians and surrounding traffic; and,

5. Hybrid cars are slow on the “take off.” Forget about gunning the engine to beat a train in a hybrid car. Entering onto a freeway or merging may not be as easy with a hybrid car. This issue alone has had many drivers wondering about safety problems.

The above examples were, or could have been, said about conventional automobiles at one time. Skepticism about anything new is common. However, skepticism is important to any decision regarding all large investments. It was probably more daunting to decide to buy an automobile in 1920 than deciding on buying a hybrid car today.

You probably have heard all the catch phrases touting the hybrid car. The “good news” is that hybrid cars are very fuel-efficient, truly environmentally-friendly, and, technologically cutting-edge—not to mention really cool. Before you write the check, though, take your time; do more research; talk to hybrid car owners; take a hide-and-watch stance. When, and if, you decide to buy, know your decision is based on information you have gathered. You wouldn’t want buyers’ remorse over a hybrid car.

HHO gas is produced from generators, fuel cells or car kits and can help you get better gas mileage. As gasoline or petrol prices climb out of sight many people are looking for relief to save money when they are at the pump. If there was a solution to build a HHO car kit from plans for any car or truck you own would you be interested?

HHO gas is also known as browns gas or simply hydroxy. This makes a nice alternative to supplement your gas as fuel prices rise. This has even been referred to as hydrogen technology but your really getting 2 gases here hydrogen and oxygen. The result is fewer emissions or pollution from the exhaust.

Through the process of electrolysis convert water to gas or better HHO gas. You may have seen an HHO car on the news but the point is you could have a hybrid water car that still runs on petrol, gasoline or diesel. You are supplementing your fuel and this will help you save fuel and increase mileage.

HHO gas generators should help you see savings of 15 – 40 % or in some cases more including possible increases in horse power and acceleration. Did you ever see this from you favorite gas supplement? You may find Free HHO plans but only the best plans should be used because they often have the detail and pictures you need to properly install the device under the hood of your car or truck.

With a set of HHO gas plans in hand this makes a great weekend project. You can easily fit this under the hood of your car and take only a few hours to install. The only requirement is about once a month or more if travel a lot is to check the water level in the HHO generator.

This technology is also being used on diesel engines and some are using it on other types of engines that run on fossil fuels. If you remember the conversions to run vehicles on propane you will find that this type of conversion is less extensive and requires minimal engine modifications.

When you have completed a HHO fuel cell consider testing it before placing it on the engine to make sure it is producing HHO gas. In some cases more HHO cells are sometimes added to further increase gas mileage.

You may be building a HHO gas generator for other reasons such as to power a riding mower or some other gasoline driven engine. Many experimenters are using various techniques to help increase HHO gas production such as pulsed current or using various catalysts in the water other than baking soda. Some of these catalysts can be vinegar or in some cases drain cleaner and there are dozens of others. Each one has its benefits.

You can find free HHO gas plans but they often are missing some details. The best plans will show you how to build a HHO generator from common parts that you may have or can purchase. Installation requires very little engine modification. Why spend several hundred dollars or more for a HHO car kit when you can build one for much less.