Project description
Innovative technology generates hollow metal components with die casting
Die casting is a common manufacturing process used to produce shaped metal parts by forcing molten metal under high pressure into reusable metal dies. The automotive industry already uses die casting to produce a variety of solid metal components. Production of hollow components currently requires additional upstream and downstream processes. The engineers behind the EU-funded MAGIT project have developed a novel gas injection technology for high-pressure die casting of hollow aluminium and magnesium parts. It promises significant savings in time, money and materials and also accommodates novel shapes such as integrated fluid duct components for the cooling of electronics and electric motors or vehicle batteries. With the EU's support, the technology is on the fast track to market uptake and deployment.
Objective
The MAGIT consortium comprises a German engineering company for product and process development (TiK), a Swiss
aluminium die casting foundry (ALUWAG), a Belgium tool manufacturer (surtechno) (all SMEs) as well as a German Foundry
Institute (Aalen University of Applied Sciences). Thus, the consortium has all necessary competences to achieve the
objectives of the FTI project.
The European automotive industry is faced with wide-ranging challenges in the common years. Especially electric mobility,
lightweight design and intelligent use of materials is essential for current and future car development. In modern cars, many
components are already produced in die casting, which is the most promising technology regarding cost-effective large-scale
production. To extend the application possibilities of this technology, a new and disrupting process was developed, which
enables the use of gas injection in aluminium or magnesium high pressure die casting and the production of components
with hollow structures. Through this, significant cost savings can be achieved by the elimination of upstream and
downstream manufacturing processes and weight can be reduced drastically by using lighter materials, but also new
constructional possibilities for complex, hollow and thin-walled components with a load-adjusted design. By MAGIT,
integrated fluid duct components can be realised. These can be used for cooling of power electronics and electric motors or
temperature controlling of vehicle batteries.
While the complex hollow components primarily address the European automotive industry, the new technology and the
MAGIT device primarily addresses the European die casting industry for non-ferrous metals. By the innovative technology,
the MAGIT consortium expects to generate additional cumulative turnover of 40 million and an increase in staff headcount
of 55 in 2024.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
- natural scienceschemical sciencesinorganic chemistryalkaline earth metals
- natural scienceschemical sciencesinorganic chemistrypost-transition metals
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Programme(s)
Funding Scheme
IA - Innovation actionCoordinator
79331 Teningen
Germany
The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.