39 www.boellhoff.com/video/helicoil-cast-for-cast-aluminium HELICOIL® Cast Stable threads for in-moulding processes – aluminium die casting That is why the future prospects for the use of aluminium in the automotive industry are promising. Uncompromising lightweight construction continues to be a focus in that industry. In view of the e-mobility of today, its significance is not lessened either — much to the contrary: not only does the vehicle mass affect the vehicle dynamics but also the range of the vehicle. The increasing share of aluminium vehicle parts in bodies and structures also requires a continuous optimisation or expansion of the product portfolio in the field of joining technologies. Taking a closer look at the trend toward extensive cast aluminium structures including the possibilities for functional integration from the perspective of high-strength screw joints, diverse challenges arise. Long flow paths and the use of secondary aluminium, which is regarded as useful from the viewpoint of CO₂ reduction, enhance the risk of porous structures and therefore also considerably increase the requirement for a load application. In addition, there are further aspects to consider such as the minimisation of material accumulations (space-optimised installation) which is a basic precondition against the backdrop of lightweight construction. Moreover, the peculiarities of electromobility require increased technical cleanliness (particle-free condition) — irrespective of whether the battery banks are integrated through functional integration in megacasting or provided as separate housings in high-voltage systems. Those high demands have been met by the HELICOIL thread technology in the semiconductor industry, in vacuum technology as well as in aeroplane engines for decades. Two current further developments in the HELICOIL product portfolio from joining technology expert Böllhoff are particularly innovative and economical. Established and innovative – HELICOIL Smart thread creation This thread insert is made of austenitic chrome-nickel steel (minimum tensile strength of 1,400 N/mm²). The high surface quality of the rolled nut thread ensures a high-strength, wear-resistant thread with an extremely small and constant thread friction torque. Therefore, a higher and constant preload-force is achieved for reuse at an equal tightening torque. Users all over the world obtain the HELICOIL Smart thread technology as an intelligent system solution comprising a fastener and efficient processing for numbers of pieces ranging from “1 to 1 million”. Innovative and new – HELICOIL Cast thread creation “in-moulding” The new HELICOIL Cast allows the creation of metallic threads in light-metal components (die-cast aluminium) through in-moulding. The thread insert consists of an asymmetric rolled A2 stainless steel wire (A4 option) which is wound to form a fixed bushing with at least one flange-like expansion. With the successful use of the IMTEC CO — its counterpart for plastic injection moulding — and the intelligent interplay of idea and innovation management, Böllhoff discovered the demand to explore the amplification of the field of use to die-cast aluminium. The focus was on two manufacturing processes during which liquid or pasty aluminium is cast or forced into pre-heated steel moulds (tools or dies) under pressure (in one case) or high pressure (in the other case). Special challenges resulted from a mass melting temperature ≥ 660°C, thermal damage to surfaces and thread inserts (effects of corrosion), an extremely low viscosity and different casting methods such as low-pressure casting (gravity casting, permanent mould casting ...) and die casting (10–200 MPa; 12 m/s). The performed tests showed that smooth core pins are sufficient for the use of the HELICOIL Cast for the low-pressure method and that spindle cores (= threads) are required for methods involving higher compressive forces in order to prevent the liquid aluminium from flowing into the internal thread. The validation tests with automatic spindle devices as well as the corrosion tests were passed on the OEM level. The user benefits from this intelligent combination among other things because of the possibility to mould functional elements directly to the component with high process reliability — functional integration. Whichever method the user chooses, in any case a wear-free and stable thread will be formed in high-quality lightweight components. www.boellhoff.com/video/helicoil-smart-automation HELICOIL® Smart The thread technology for high-strength joints in automation presse@boellhoff.com www.boellhoff.com/de-de Contact
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