Describe design, casting and molding requirements for castings and their function, including assembly components:
Cylinder head cover for high-performance engines is consistently lightweight thanks to a wall thickness of just 2 mm and use of a creep-resistant magnesium alloy in die-casting.
Design, casting and styling requirements:
Standardized casting blank for mirror-symmetrical finished parts of left and right cylinder blocks as a machining variant; porosity/gas-tightness ensured by use of core pullers, extruders and pre-cast sealing grooves.
Why use die castings?
Cylinder head cover was originally planned to be investment cast in aluminum. Difficulties encountered during manufacturing process resulted in need for reevaluation. Despite high investment in tooling, die castings outperformed milled aluminum parts and rapidly formed aluminum cylinder heads due to their small wall thickness and good lightweighting potential due to use of magnesium alloy (30% lighter).
Why does this part deserve European Diecast Award?
1. Technically advanced large-area, thin-walled, oil-tight die castings made of creep-resistant magnesium alloy, suitable for high-pressure applications in powertrain field.
2. Die castings produced in small batches also have manufacturing advantages and are 30% lighter, thereby increasing profitability.
3. Two mirror-symmetrical finished parts are made of standardized casting billets, saving investment.
Technical specifications
Length: 733mm
Width: 284mm
Height: 59mm
Weight: 1625 g
Alloy: AE44
Submitting company: Audi AG

 

Describe design, casting and molding requirements for castings and their function, including assembly components:
Console serves as connection between cockpit cross member and steering column.
Design, casting and styling requirements:
Double-cavity die-casting mold has 4 sliders per cavity. Due to their geometry, some of these sliders have to be pulled in at an angle. Shaping and stamping are fully automatic. One challenge here was jetting because casting tree was wider than die casting machine's column channel, so a self-retracting jet head was used. In addition, spray media can be saved by spraying small amounts. Another challenge was long flow path since parts were filled lengthwise. A partial erosion structure is also used to prevent cracking. Technical deburring is performed by zinc spraying. Finally, dimensionally demanding CNC machining is carried out, followed by cleaning.
Why use die castings?
Lighter weight compared to materials like steel plate or aluminum. Structural connection of multiple components using a single component. Good impact properties: high elongation and energy absorption at high strength.
Why does this part deserve European Diecast Award?
This part represents main advantage of magnesium die casting. It has high design freedom, lightweight structure, excellent mechanical properties (especially rigidity), and can replace multiple separate parts with one part.
Casting resources are saved due to reduced spray volume. Advanced production technology.
Technical specifications
Length: 330mm
Width: 204mm
Height: 100mm
Weight: 740 g
Alloy: AMZ40
Submitting company: PC Zitzmann GmbH&Co.

 

Describe design, casting and molding requirements for castings and their function, including assembly components:
Housing impresses with its high precision and low weight without need for machining. This brings cost advantages to customers as it projects a clear image onto windshield via a light source and several reflectors.
Design, casting and styling requirements:
Required mold filling time is very short (2 pours). Geometry of central open area was difficult to fill and flow well due to effects of cast shadows. Filamentous parts with solid parts must be preformed using special slides (temperature exceeds 250℃).
Why use die castings?
Production of such components is ideally suited to die-casting process, since applications in automotive industry require high quantities, stringent requirements for lightweighting, high requirements for functionality and process stability. Using magnesium alloys it is possible to cast very light, thin-walled components that reproduce all functions in original silhouette.
Why does this part deserve European Diecast Award?
1. The first generation head-up display housing requires no machining and has very thin walls.
2. Requires highly complex and precise casting mold, multi-cavity (2 layers)
3. There can only be very small process window (thermal runout) tolerances in die casting process.
4. Adopt a new sub-process of dry ice deburring and cleaning (reason: reduce deformation caused by spraying, higher purity, low amine concentration)
Technical specifications
Length: 486 mm
Width: 285 mm
Height: 184mm
Weight: 1168 g
Alloy: AZ91 (MgAl9Zn1)
Submitting company: TCG UNITECH GmbH TCG UNITECH GmbH

 

Describe design, casting and molding requirements for castings and their function, including assembly components:
Visible parts, smooth and clean surfaces, precise dimensional accuracy and angles, precise achievement of closely spaced ribs on both sides.
Design, casting and styling requirements:
Dimensional accuracy, angles, tight casting tolerances, tight machining tolerances (as installation in installation must be guaranteed), clean surfaces, painted or powder-coated visible parts.
Why does this part deserve European Diecast Award?
Sand cast prototypes, examples of industrial applications including electric vehicles and medical technology, where complexity and difficulty of parts, tight rib designs require maintaining a strict heat supply.
Technical specifications
Length: 354mm
Width: 343mm
Height: 33 mm
Weight: 2740 g
Alloy: AZ91
Submitting company: Metal foundry Stauß KG

 

Describe design, casting and molding requirements for castings and their function, including assembly components:
Visible parts, smooth and clean surfaces, precise dimensional accuracy and angles, wall thickness 6 mm, visible grooves of 3.5 mm had to be milled, weight reduction due to use of magnesium, extended range of applications (suspension).
Design, casting and styling requirements:
Dimensional accuracy, angles, strict casting tolerances, strict machining tolerances, as it must be installed in relevant device, surface is clean, and visible parts are painted or powder coated.
Why does this part deserve European Diecast Award?
Sand cast prototypes, examples of industrial applications (including electromechanical and medical technology), complexity and difficulty of components, requirements for tight tolerances, thin walls, large surfaces, dimensional stability, design and surfaces.
Technical specifications
Length: 481 mm
Width: 397 mm
Height: 132mm
Weight: 4040 g
Alloy: AZ91
Submitting company: Metallgießerei Stauß

 

Describe design, casting and molding requirements for castings and their function, including assembly components:
Visible areas, casting is very good, no damage allowed.
Design, casting and styling requirements:
No flash is allowed on parts and casting quality is very good.
Why use die castings?
Reduce machining, special requirements
Why does this part deserve European Diecast Award?
High quality features (cast and coated)
Technical specifications
Length: 45.5mm
Width: 29 mm
Height: 29mm
Weight: 5.86 g
Alloy: AZ91D
Submitting company: Dynacast Deutschland GmbH