UQ researchers help Ford's wheels turn more efficiently
Major improvements to the heat treatment phase in car wheel manufacture by a team of University of Queensland researchers have saved Ford New Zealand an estimated $1 million.
The work by University of Queensland-based CAST researchers involved optimising the heat treatment processes used to strengthen aluminium castings.
This world-class expertise was honed during previous work on reducing solution treatment times carried out with Southern Aluminium during 1995-96.
Ford New Zealand Alloy Wheel Plant Production Manager Geoff Martin said the boost in productivity as a result of the work had saved the company over $1 million.
"This is highly relevant to the continuing competitiveness of the Plant's export operation whose main customers are the North America market," Mr Martin said.
"We are extremely happy with the way in which CAST have run the project - the thoroughness of the research, the team approach with Plant personnel as well as maintaining cost and timing objectives reflect the professionalism of the CAST team."
Led by the Chair of Solidification Technology with CAST at the University, Professor David StJohn, the collaboration began four years ago and has since led to similar work with Melbourne-based PBR Automotive.
Other research teams members from the University of Queensland were Dr Roman Schmidt, Dr John Taylor and research assistant Li Zheng. Dr John Griffiths of CSIRO Manufacturing Science and Technology completed the team.
"Heat treatment processes change the microstructure of aluminium in two stages - solution treatment and ageing," Professor StJohn said.
"In both stages, the components are held at elevated temperatures for prescribed periods of time. The ability to reduce the time for these steps while retaining the improved microstructural outcomes increases productivity through time saved and reduces energy consumption of the process."
All research was conducted using laboratory and testing facilities at the University's Department of Mining, Minerals and Materials Engineering.
In 1999, CAST received renewed Federal and State Government funding of $30 million over the next seven years to help place Australia at the forefront of the world light metals industry.
In addition, CAST has substantial industry backing raising the net worth of the Centre's activities to more than $100 million.
The University is one of five founding partners in the Centre set up six years ago to investigate the properties and potential of light metals.
Light metals such as magnesium, aluminium and titanium are the metals of the future, highly sought after by the world's automotive industry to make lighter, more fuel-efficient cars.
CAST director Professor Gordon Dunlop said with the world-wide move towards decreasing car emissions, aluminium and magnesium were especially sought after by the automotive industry to manufacture lighter car components.
For more information, contact Professor Gordon Dunlop (telephone 07 3365 3641).
