Periodic Reporting for period 4 - MAGIT (Magnesium and Aluminium Gas Injection Technology for High Pressure Die Casting)
Période du rapport: 2023-09-01 au 2024-08-31
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 54-month project duration, the focus was on production of process stable MAGIT 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 54-month project duration, the focus was on production of process stable MAGIT 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.
Besides this, a five-legged swivel chair cross from the furniture industry was chosen as the integrative lightweight component. The MAGIT chair-cross could be developed, the mould was manufactured and casting trials were performed with the chair cross. The chair-cross was a very complex component. In the meanwhile the experiences made in this first project are currently transferred to another customer in the furniture industry.
Also 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 new component could be developed, the mould was manufactured and four casting trials have been carried out within the project.
All the experiences made within these projects could be transferred into completely new developed demonstration parts, which were produced by Aluwag.
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 were continously optimised.
During and up to the end of the project, all relevant OEMs and Tier 1 in the European automotive industry were contacted and MAGIT could be presented in detail. Due to this, feasibility studies were carried out with a large number of these companies or sample components could already be developed and casted. Thanks to these measures and the strong presence at the leading trade fair Euroguss in 2022 and 2024, the technology could penetrate the die casting and automotive industry and the leading companies are now familiar with the technology.
Besides this, a five-legged swivel chair cross from the furniture industry was chosen as the integrative lightweight component. The MAGIT chair-cross could be developed, the mould was manufactured and casting trials were performed with the chair cross. The chair-cross was a very complex component. In the meanwhile the experiences made in this first project are currently transferred to another customer in the furniture industry.
Also 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 new component could be developed, the mould was manufactured and four casting trials have been carried out within the project.
All the experiences made within these projects could be transferred into completely new developed demonstration parts, which were produced by Aluwag.
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 were continously optimised.
During and up to the end of the project, all relevant OEMs and Tier 1 in the European automotive industry were contacted and MAGIT could be presented in detail. Due to this, feasibility studies were carried out with a large number of these companies or sample components could already be developed and casted. Thanks to these measures and the strong presence at the leading trade fair Euroguss in 2022 and 2024, the technology could penetrate the die casting and automotive industry and the leading companies are now familiar with the technology.
In the the last reporting period new demonstration parts (power electronics housing) could be developed and produced. With these parts serial production could be validated. Within the last reporting period these demonstration parts could be shown on the leading trade fair Euroguss and could be shown to potential customers.
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.
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.