search

Select Language

Home
Yamaha Global Links
Japanese Site

Global Home
Global News Center
2002
A new die-cast method for manufacturing innovation "Yamaha CF Aluminum
Die Casting Technology" Developed Making possible the mass production of
large but thin aluminum die-cast parts

A new die-cast method for

manufacturing innovation "Yamaha CF
Aluminum Die Casting Technology"
Developed Making possible the mass

production of large but thin aluminum

die-cast parts
February 05, 2002

Yamaha Motor Co., Ltd. (YMC) has succeeded in the development of a new
manufacturing technology called the Yamaha CF Aluminum Die Casting
Technology* that enables the mass production of large but thin aluminum die-cast
parts in an environment-friendly, low-cost way that will contribute significantly to
manufacturing innovation.
* CF Die Casting = Controlled Filling Die Casting
Aluminum die casting is a technology that brings excellent manufacturing productivity
to aluminum parts, with their inherent qualities of light weight, rust resistance and
recyclables. As a result, die-cast aluminum parts are used in large numbers in
motorcycle engines and chassis as well as outboard motors. However, with
conventional die casting there has always been a limit to the thinness of sections in a
cast piece in relationship to its overall size. That is why it has long been difficult in the
industry to produce die-cast parts that are both large overall and thin in some sections.
Furthermore, with the present trend toward environmental concerns resulting in the shift
to 4-stroke engines and the addition of exhaust-cleaning devices which increase both
the weight and number of parts for future models, it is believed that the keys to
manufacturing innovation will be lightening technologies in combination with measures
that reduce cost and improve fuel efficiency.
The newly developed Yamaha CF Aluminum Die Casting Technology is a process
that enables mass production of aluminum die-cast parts that are both large and thin in
sections, thus making it a technology that answers todays social needs by enabling the
production of lighter products with fewer parts. Focusing on improving the flow
characteristics of the molten aluminum as it is poured into the metallic mold (die),
Yamahas new technology greatly improves the smoothness of the flow into the die by
(1) increasing the vacuum inside the die, (2) regulating the temperature of the die and

(3) improving the injection speed of the molten aluminum. The combined effects of
these measures enable the mass production of high-quality die-cast aluminum parts with
an air-intrusion rate (cause of air bubbles) of about one-fifth that of conventional die
casting.
The introduction of this new technology to the manufacturing process can result in
about a 30% reduction in part weight and 80% reduction in the number of parts
necessary. Furthermore, the reduction in the amount of aluminum used and the
simplification of the manufacturing process will bring an estimated 30% reduction in
cost compared to the conventional die casting method. And, because it does not require
specialized aluminum alloys, this technology can be readily transferred to overseas
manufacturing bases on the condition that the metallic molds be changed as well.
At Yamaha we will apply of this technology to a wide range of products such as
motorcycles and outboard motors.

Comparison of CF Aluminum Die Casting and other conventional die-cast methods

Minimum piece thickness(mm)

Summary of the Technology

Due to the controlled conditions under which the molten aluminum is injected into the
metallic mold (die) at high speeds and high pressure in conventional high-pressure die
casting, a certain amount of air and oxides inevitably enter along with the aluminum,
resulting in generating air bubbles in the final cast metal. As a result, there was a limit
to how thin sections of the cast parts could be and how sharp the curves in the parts
could be. This was a weakness of the conventional die casting method that left room for
improvement. The Yamaha CF Aluminum Die Casting Technology is the result of
development efforts focused on the shaping technology applied to aluminum die-cast
parts in order to improve on this weakness.
The technical focus in developing this new method was to optimize the flow
characteristics of the molten aluminum to obtain the best possible flow into the die in
the short time before the aluminum begins to solidify, with optimum evenness in the
final lie of the aluminum before it hardens.
To achieve this, we built on the technological base acquired from our long years of
experience in vacuum aluminum die casting and added an exclusive new method for
improving the completeness of the vacuum in the die which also made possible more
precise control of the various aspects of the casting process. Specifically speaking, we
optimized the conditions of the molten aluminum injection into the die by (1)
introducing an exclusively developed new type of seal material for sealing the die parts
together to increase the completeness of the vacuum inside the mold and reduce the air
resistance (six fold improvement over conventional method), (2) controlling the
temperature of the mold in order to achieve a more stable temperature in the molten
aluminum and, (3) increasing the speed of the molten aluminum injection (five times
over conventional method). The combined effect of these measures reduced the amount
of air (gases) in the resulting cast metal to one-fifth the amount of the conventional

method. This results in a stronger quality aluminum that, unlike conventional die-cast
aluminum, is strong enough to be welded, which in turn makes possible the mass
production of aluminum die-cast parts that are both large and thin in relevant sections.
This new method makes it possible to manufacture aluminum parts with the high
efficiency of high-pressure die casting, and with strength and stretchability equal to
gravity casting. Also, this has made it possible to produce the kind of large but thin
aluminum die-cast parts that were difficult under the conventional die casting methods.
Furthermore, since this new method enables the mass production of cast aluminum
parts designed for extreme thinness and more complex curves, it will suggest new
design standards for cast aluminum parts.

Conventional Aluminum
Die casting Technology
Yamaha CF Aluminum Die Casting Technology
Characterized by (1) seals inserted between mold
sections to increase vacuum completeness,
(2) stabilization of the molten aluminum temperature by
controlling mold temperature,
(3) improved injection speed for the molten aluminum.

Reference

Development Background
Amid the increasing concern for environmental preservation, there has been a rapid
shift toward 4-stroke engines for motorcycles and outboard motors, as well as the
adoption of emissions-reducing catalyzers and electronic fuel injection systems. There

has also been an increasing movement toward hybrid vehicles, all of which has resulted
in a revolution in vehicle engine and chassis design. Naturally, there is a concern that
these additional systems will increase the weight of engines. Accordingly, the key is to
use lightweight aluminum and lightweight design technologies to cancel out this added
weight so that products can maintain past performance levels or even improve on them.
Aluminum is about 34% lighter than steel and is also excellent for casting thanks to its
low melting point and good flow characteristics. Aluminum is also easier to reuse than
other metals and there is almost no difference in the quality of the metal produced from
recycled aluminum compared to new stock. Also, by combining it with other metals and
selecting different kinds of thermo physical methods, it can be made to fit the needs of
different uses. Taking advantage of these beneficial qualities, Yamaha uses aluminum in
many of its products.
Particularly in products like motorcycles, snowmobiles and personal watercraft with
which customers enjoy the handling and the feeling of man-machine unity that
results, we at Yamaha consider reducing weight to be an important part of our
manufacturing innovation process. And, one of the ways we reduce weight is by
introducing aluminum parts. Presently, the ratio of aluminum (by weight) in our
outboard motors is about 50%, while our large-class motorcycles are about 40%. And,
as seen by the fact that we use about 3,000 tons of aluminum a month in our factories,
improving the quality, the amount, and manufacturing process of aluminum parts has a
vital effect on our products from their cost to their quality.
Against this backdrop, Yamaha CF Aluminum Die Casting Technology has developed
with the result of our research, development and practice of aluminum die-casting in
order to realize our manufacturing innovation.

This super-sport model YZF-R1 is 40%

aluminum by weight.

The outboard motor is 50%

aluminum by weight.
(Photo:Yamaha F200)

Aluminum weight ratio for Yamaha products