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.
