Alumimium die casting competition at the Euroguss

The winners of the aluminium die-casting competition were honoured at Euroguss. First prize was awarded to Hengst SE for an oil center cooling module.

The competition is organised by Gesamtverband der Aluminiumindustrie (GDA). It is supported by the Federal Association of the German Foundry Industry, the Swiss Aluminium Association and the Non-Ferrous Metals Industry Association in the Austrian Federal Economic Chamber.

The award ceremony is intended to draw the public's attention to innovative technologies from aluminium die-casting. In the evaluation of the submitted pressure die castings, the jury of experts from research and practice judged the die-castable and resource-saving design.

The prizewinners are:

1st price: Oil-coolant module
Hengst SE, Nordwalde, Deutschland
Alloy: AISi9Cu3(Fe)
Weight: 8.655 g
Dimension: L 443 mm x, B 340 mm x, H 195 mm

The prize is awarded for the consistent and obviously taboo-free development methodology, which is geared towards optimum results, from casting design to tool design and casting process. Decisive factors were the complex geometry with underfloor slides and minimal draft angles and low tolerances, while at the same time meeting the highest demands for pressure tightness. The intensive temperature control with all technically available means appears particularly impressive.

2. price: housing HV-Booster
Druckguss Westfalen GmbH & Co. KG, Geseke, Deutschland
Alloy: EN AC-AISi10MnMg
Weight: 2.785 g
Dimension: L 344 mm x B 365 mm x H 176 mm

The prize is awarded for a high-function integrated die-cast part in which water-bearing cooling areas are arranged next to electrical high-voltage areas with the highest sealing requirements. The high rigidity and dimensional accuracy was solved against the background of thin wall thicknesses with stiffening ribs. The low copper alloy ensures high corrosion resistance and strength in the cast state.

3. price: upper housing part for 2 channel EBS
Alupress AG, Brixen, Italien
Alloy: EN AC-47100
Weight: 780 g
Dimension: L 193 mm x B 98 mm x H 98 mm

The prize is awarded for a die-cast part that is subject to high safety requirements. Compared to plastic injection moulded parts, this aluminium die-cast part has prevailed due to dimensional accuracy with the smallest tolerances and minimum radii, tightness and surface qualities for finish-cast sealing surfaces. Remarkable is the assembly-ready casting of the component. The innovative and efficient temperature control system with additively manufactured tool segments was also positively evaluated.

3rd price: battery case
Nemak Slovakia s.r.o., Žiar nad Hronom, Slowakei
Alloy: AlSi9Mn (naturhart ohne Wärmebehandlung)
Weight: 15.900 g; Guss mit Bodenplatte Extrusion 38.000 g
Dimension: L 1045 mm x B 753 mm x H 218 mm

The award is for a hybrid battery housing which was cast on a 4400 t machine with a complex 3-plate tool with 4 external slides in vacuum die casting. The cast component is joined by friction stir welding (FSW) with three extrusion profiles forming the bottom of the housing. This ensures the best possible protection against strict leakage requirements (helium leakage test). The use of a naturally hard alloy means that heat treatment is not necessary.


Two other castings received awards as "special recognition":

"Special recognition": housing component for a control unit for electric vehicles
Alupress AG, Brixen, Italien
Alloy: AISi12(Fe)a
Weight: 1.450 g
Dimension: L 350 mm x B 175 mm x H 70 mm

With this cast part, it was acknowledged that the high level of functional integration saves up to 30% in installation space and weight. An intelligent liquid cooling system with a laser-welded housing cover was implemented in the casting. In terms of design, this meant an adaptation of the original design and local mass reduction. By using laser welding as a joining method, a significant reduction in cycle time could be achieved. In addition, the overall concept resulted in a cost-effective solution.

"Special recognition": String inverter
FBL Pressofusioni srl, Vobarno, Italien
Alloy: EN AC-46000
Dimension Internal parts (2)
L: 533 mm x B: 386 mm x H: 266 mm
Weight: 9.700 g / 9.600 g
Dimension: Outdoor units (2)
L: 705 mm x/ 704 mm x B: 527 mm x/ 527 mm x H: 150 mm / 150 mm
Weight: 12.000 g / 7.000 g

A 4-part string inverter with a high level of functional integration and the possibility of mounting the internal electrical components is being honoured. The cast parts are characterised by deep ribbing for cooling the housing. Also positively evaluated is the consistent methodology for the development of the casting system with the aim of reducing or non-critical distribution of porosity.