New generation of digital material for automotive components

Ni-Cr-Si-Fe-B self-fluxing alloys are commonly used in hardfacing applications; in addition, they are subjected to conditions of wear, corrosion, and high temperatures, but are not used in casting applications. In this work, gravity casting is presented With the application of Industry 4.0 technology, a new generation of advanced materials is developing in the world of safety components for automotive brake parts in ductile cast iron. A significant reduction in weight could be obtained than to outstanding increase in their mechanical properties whose Yield Strength goes from the standard 370MPa up to 420MPa with an Ultimate Tensile Strength around 700MPa and an elongation higher than 5%.

The achievement of these objectives is due to the development of a Smart module that contains intelligent algorithms capable of connecting the characteristics of the process with the properties of the material, intelligently reducing the gap between the process control limits.

The methodology used is based on the capture of the relevant data of the process, the detection of the most influential parameters, the development of intelligent algorithms that give rise an online prediction of the component’s properties based on its manufacturing, assuring the quality of the new grade.