Periodic Reporting for period 2 - MAGIT (Magnesium and Aluminium Gas Injection Technology for High Pressure Die Casting)
Reporting period: 2021-03-01 to 2022-02-28
MAGIT production technology enables the production of complex hollow structures inside castings directly in the high pressure die casting (hpdc) process. During casting solidification, a process gas is injected into the casting with a patented gas injector, the residual melt is displaced into a spill-over cavity and thus a defined hollow structure is produced.
In the MAGIT project, the advantages of gas injection technology in hpdc casting will be further developed in relation to the new possibilities of casting design as well as component cost reduction for applications suitable for industrial use for the large series die caster and implemented in large series production.
Complex and hollow lightweight components for weight reduction as well as components with a fluid ducting channel, for example for the thermal management of an electrical engine, are becoming increasingly important due to the increasing electrification of road traffic and the targets of European environmental policy.
The application of MAGIT (magnesium and aluminium gas injection technology) production technology in large series production will make a significant contribution to the electrification of road traffic and to achieving the challenging, European environmental targets. MAGIT is based on the gas injection technology (GIT) principle used in plastic injection moulding.
Advantages of the MAGIT process result on the one hand from the new possibilities for component design through function integration and part substitution. This eliminates time-consuming additional processes such as mechanical machining, the joining and gasketing of individual components. The flexible design of component connection points is made possible; for example, hose nozzles can be attached directly to the casting in the hpdc process. Component costs are thus reduced by material savings and the elimination of costly pre- and post-processes.
On the other hand, parts substitution opens up production capacity on the hpdc machines, enabling the die caster to acquire further customer orders.
Within the 36-month project duration, the focus is on the market launch of MAGIT suitable for large-scale production of hollow lightweight components as well as fluid ducting hpdc components.
The MAGIT power module enables the independent production of two hollow channels, which is of high relevance especially for hpdc moulds with multiple cavities. By recording quality-relevant hpdc machine data and process data, mould temperature and cavity pressure, the quality of the MAGIT castings produced can be ensured and monitored. The interface between the hpdc machine and the MAGIT power module is designed for the foundry environment and is easy to set up due to a small number of plug-in connections that are insensitive to contamination.
In addition to plant technology and the associated service as well as training, the MAGIT project consortium offers competent support in the area of component and process consulting. This includes the sub-areas of MAGIT-compatible component development, process simulation, tool design, process optimization and component testing.
In the MAGIT project, the advantages of gas injection technology in hpdc casting will be further developed in relation to the new possibilities of casting design as well as component cost reduction for applications suitable for industrial use for the large series die caster and implemented in large series production.
Complex and hollow lightweight components for weight reduction as well as components with a fluid ducting channel, for example for the thermal management of an electrical engine, are becoming increasingly important due to the increasing electrification of road traffic and the targets of European environmental policy.
The application of MAGIT (magnesium and aluminium gas injection technology) production technology in large series production will make a significant contribution to the electrification of road traffic and to achieving the challenging, European environmental targets. MAGIT is based on the gas injection technology (GIT) principle used in plastic injection moulding.
Advantages of the MAGIT process result on the one hand from the new possibilities for component design through function integration and part substitution. This eliminates time-consuming additional processes such as mechanical machining, the joining and gasketing of individual components. The flexible design of component connection points is made possible; for example, hose nozzles can be attached directly to the casting in the hpdc process. Component costs are thus reduced by material savings and the elimination of costly pre- and post-processes.
On the other hand, parts substitution opens up production capacity on the hpdc machines, enabling the die caster to acquire further customer orders.
Within the 36-month project duration, the focus is on the market launch of MAGIT suitable for large-scale production of hollow lightweight components as well as fluid ducting hpdc components.
The MAGIT power module enables the independent production of two hollow channels, which is of high relevance especially for hpdc moulds with multiple cavities. By recording quality-relevant hpdc machine data and process data, mould temperature and cavity pressure, the quality of the MAGIT castings produced can be ensured and monitored. The interface between the hpdc machine and the MAGIT power module is designed for the foundry environment and is easy to set up due to a small number of plug-in connections that are insensitive to contamination.
In addition to plant technology and the associated service as well as training, the MAGIT project consortium offers competent support in the area of component and process consulting. This includes the sub-areas of MAGIT-compatible component development, process simulation, tool design, process optimization and component testing.
At the beginning of the project, the previous research results were used to optimize two existing hpdc moulds. The two mould concepts were jointly developed and realized in the project consortium. In particular, optimizations were implemented to improve the surface quality of the hollow channel through the casting geometry and the design of the spill-over cavity.
First casting trials with the first mould have already been carried out. Casting trials with the second mould are still pending, because the mould is currently in manufacturing.
A five-legged swivel chair cross from the furniture industry was chosen as the integrative lightweight component. The MAGIT concept for the production of the chair cross and a preliminary tooling concept have already been developed in the project consortium. Within the second reporting period the mould was manufactured and first promising casting trials were performed.
A clutch cover from the automotive industry with an integrated oil channel for cooling transmission components was chosen as the fluid ducting component. The MAGIT concept for the production of the casting with integrated channel has already been developed in the consortium and the mould was manufactured. The casting trials with the clutch cover mould are envisaged as a next step.
For the industrial application of the MAGIT process, a modular MAGIT power module was developed and manufactured which can be adapted to the specific customer requirements. Within the project, the MAGIT module and the software are continously optimised.
So far many potential customers and interested parties in the foundry, automotive but also other industries were contacted as part of the sales activities and the concept of MAGIT production technology was presented and propagated. As a result, first sales of the MAGIT devices can be assumed until the end of the project.
First casting trials with the first mould have already been carried out. Casting trials with the second mould are still pending, because the mould is currently in manufacturing.
A five-legged swivel chair cross from the furniture industry was chosen as the integrative lightweight component. The MAGIT concept for the production of the chair cross and a preliminary tooling concept have already been developed in the project consortium. Within the second reporting period the mould was manufactured and first promising casting trials were performed.
A clutch cover from the automotive industry with an integrated oil channel for cooling transmission components was chosen as the fluid ducting component. The MAGIT concept for the production of the casting with integrated channel has already been developed in the consortium and the mould was manufactured. The casting trials with the clutch cover mould are envisaged as a next step.
For the industrial application of the MAGIT process, a modular MAGIT power module was developed and manufactured which can be adapted to the specific customer requirements. Within the project, the MAGIT module and the software are continously optimised.
So far many potential customers and interested parties in the foundry, automotive but also other industries were contacted as part of the sales activities and the concept of MAGIT production technology was presented and propagated. As a result, first sales of the MAGIT devices can be assumed until the end of the project.
In the next steps further extensive casting trials are planned with the chair cross and the clutch cover moulds. With these moulds serial production can be validated. This is very important as many future potential customers see this as prerequisite for implementation of the technology.
Besides this further casting trials will be performed with the HTWA cover. In particular, the surface quality of the hollow channels and the reproducibility of the quality are to be increased. Measures to ensure this have already been taken into account in the mould design. Investigation of the influence of the different spill-over cavities as well as the influence of the casting alloy are further investigated.
By the project a high impact is expected as the technology enables new design possibilities with great material and weight savings. In addition, by MAGIT fluid duct components can be realised. Through this application possibility, a high impact for the European automotive industry is expected. To increase awareness of MAGIT the Euroguss in June 2022 is a key fair to adress relevant stakeholders of the technology.
Besides this further casting trials will be performed with the HTWA cover. In particular, the surface quality of the hollow channels and the reproducibility of the quality are to be increased. Measures to ensure this have already been taken into account in the mould design. Investigation of the influence of the different spill-over cavities as well as the influence of the casting alloy are further investigated.
By the project a high impact is expected as the technology enables new design possibilities with great material and weight savings. In addition, by MAGIT fluid duct components can be realised. Through this application possibility, a high impact for the European automotive industry is expected. To increase awareness of MAGIT the Euroguss in June 2022 is a key fair to adress relevant stakeholders of the technology.