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PAGE 1

Formula 1 technology for street use

SMW ENGINEERING SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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COMPANY PROFILE RELIABILITY. QUALITY. INNOVATION. SMW Engineering (SMW) holds top expertise in the field of Mg and Al semi-finished and finished products and technologies for lightweight applications. The Company is a global leader in the production of Mg forged alloy wheel blanks, forged alloy wheels, cast Mag alloy wheels and other Mg and Al components. SMW develops advanced state-of-the-art technologies and further offers best in class engineering services.

Development of new alloys

New hybrid and reinforced materials

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

Downstream production

Ultra-light metallurgical components

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Development of the company

HISTORY

SMW was established in 1996 in Russia as a sister company of the Russian Institute of Titanium and Magnesium, both affiliated with Solikamsk Magnesium Works, Russia's largest and oldest magnesium smelter and research facility - producer of magnesium and alloys, titanium sponge, tantalum and niobium oxides and rare-earth derivatives. Since then SMW team of professionals was joined by the specialists from the magnesium engineering department of the Russian National Aluminum-Magnesium Institute, renowned for their numerous international engineering projects across the world. This esteemed team of experts is responsible for the development, manufacture and supply of lightweight applications deploying proprietary and generic magnesium, aluminum-lithium and other aluminum-based specialized alloys and hybrid materials.

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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SMW Processes and Technologies Best in class – for F1 and beyond

• • • • • • • • •

3-D precision hot forging to manufacture forged Mg & Al alloy monoblock blanks/wheels precise and light forging with a near-net configuration obtained with proprietary 2-step forging process powerful hydraulic presses (10,000 to 30,000 tons force) 1-piece wheel with uniformly excellent properties in the hub, spokes as well as in the rim area close tolerances (max. 3-4 mm) - less machining needed - less interference with the metal fiber structure -- yielding superior mechanical properties throughout the wheel rim area (well and bead seat) is shaped during the forging process (no spinning involved) – unparalleled properties in the rim capability to forge a spoke pattern providing excellent strength characteristics in the spokes due to metal flow for optimized grain and fiber structure and minimizing design machining required capability to produce forgings in both Al and Mg alloys using the same tooling/moulds ISO and TUV certified systems of quality control

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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Some of SMW clients include…

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Our Clients: Testimonials

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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Prime choice of Formula 1, MotoGP and SuperBike champions

SMW wheels:     

special 3D forging process unparalleled grain structure optimized metal flow fibers alloy modification for higher properties weight-reduction and top characteristics

All magnesium wheels for Ducati are produced by SMW – including Superleggera and other models

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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SMW – highly respected for world’s top quality wheels


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SMW Wheels used for Formula 1 highest demands

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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SMW products selected by world’s top three moto racers They all ride on SMW forged wheels

Jorge Lorenzo

Valentino Rossi

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

Pol Espargaró

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SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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Benefits Of Forged Magnesium Wheels

• • • • • • • • •

improved vehicle performance better acceleration shorter braking distance improved safety and maneuverability fuel savings (up to 5-7%) increased service life and reliability of suspension components reduction of CO2 emissions improved performance and service life of brake system higher driving comfort due to reduced vibrations

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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PAGE 12

Process Flow

1

Selection of lightweight materials and alloys

2

6

Component analysis and definition of requirements

Prototype testing

3

7

Design, computer modeling and engineering analysis of designed component

Design correction (optional)

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

4

8

Manufacturing specifications

5

Prototype production

Design, computer modeling and engineering analysis of designed component

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Keys To Success ZK60A Forging Technology MATERIAL High-strength magnesium alloy ZK60A is used. In comparison to the other high-strength

alloys,

e.g.

AZ80A,

ZK60A

has

a

number

of

advantages.

Better mechanical properties (while ZK60A’s and AZ80A’s tensile yield strength and cyclic fatigue are equal, ZK60A’s relative elongation is 1,5 – 2 times higher) • Less susceptible to stress corrosion cracking • Lack of metal impurities (Fe, Cu, Ni) • Better “forgeability”, ZK60A’s resistance to deformation is 1,2 times less, which allows to perform forging operation under lower temperatures PROCESS The metal structure of ZK60A alloy prior to forging is controlled by conducting a preliminary operation where poor quality zones such as undissolved eutectics on the grain boundaries, intermetallic compounds, etc. are destroyed. Forging presses of 10,000-15,000 ton capacity are used to perform the final forging operation under lower temperatures. The forged metal structure features a smaller than usual grain size which ultimately leads to the increase of wheels life cycle.

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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A

B

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Product Samples

A. Forged alloy wheel, 12 spoke Size: 22" X 9.5" Alloy: AV/6061/ZK60A

B. Forged alloy wheel, 7 spoke Size: 22" X 9.5" Alloy: AV/6061/ZK60A

C. Forged alloy wheel, Werner Size: 17" X 7.5" Alloy: AV/6061/ZK60A

C

D

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

D. Forged alloy wheel, Star Size: 17" X 7.5" Alloy: AV/6061/ZK60A

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PAGE 15

Overview of Mechanical Properties in Wheel Forgings Alloy grade

UTS (MPa)

YTS (MPa)

Elongation (%)

Hardness (HB)

Remarks

ZK60A (spokes)

265

-

6

60

Minimum

ZK60A (rim)

255

-

6

60

Minimum

ZK60A (hub)

245

-

6

60

Minimum

ZK60A

300

160-230

7-10

72

Typical

ZK60A

315

255

14

65

Enkei’s test results

MA2-1

255

-

7

-

Minimum

MA2-1

260-275

165-200

11-15

52

Typical

AZ80A

270-315

160-240

4-4,5

-

Typical

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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PAGE 16

Measured Properties in Wheel Forgings Test results for a 3,5” X 17” forged motorcycle wheel blank made from MA14 (ZK60A) alloy

Specimen#

Location

UTS (kgs/mm2)

YTS (kgs/mm2)

Elongation (%)

Hardness (HB)

1-1

Rim

25,9

20,3

8,0

51

1-2

Rim

26,8

21,4

8,0

-

2-1

Rim

27,6

22,0

11,2

-

2-2

Rim

26,9

20,3

14,4

-

3-1

Spoke

26,7

19,0

16,0

-

3-2

Spoke

27,1

25,1

12,0

-

4-1

Hub

24,3

10,2

15,2

-

4-1

Hub

24,6

10,5

15,2

-

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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PAGE 17

Measured Properties in Wheel Forgings Test results for a forged motorcycle wheel made from ZK60A. Over 12% elongation is a major achievement

Specimen #

Diamete r (mm)

Cross section (mm2)

Length (mm)

UTS (MPa)

YTS (MPa)

Elongation (%)

1

11,3

100,2

56

267

112

12,6

2

11,3

100,2

56

278

148

14,8

3

11,3

100,2

56

258

88

13,6 Testing direction is indicated by arrows

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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PAGE 18

FEA analysis: F1 wheels

BUMP

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

CORNERING

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PAGE 19

Our contacts Where you can find us

Telephone

Email

Website

Address

www.smw.com

Nab. Chernoi rechki 41B St. Petersburg, Russia, 197342

@ +7.812.496.2217

smwe@smw.com

SMW ENGENEERING NAB. CHERNOI RECHKI 41B, ST. PETERSBURG, RUSSIA | TEL: +7.812.496.2217 | FAX: +7.812.295.2540 | E-MAIL: SR@SMW.COM

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SMW Engineering Wheels Presentation 2014