Casting process - integrity and accuracy

MAHLE Powertrain's foundry delivers high strength, lightweight aluminium castings for prototypes or series manufacturing, with outstanding dimensional precision, integrity and freedom from residual stress.

Our in-house facilities at Worcester, UK, site include a metallurgical laboratory, real time x-ray monitoring, both static and portable co-ordinate measuring machines and electromagnetic pump metal delivery system manufacture. All are supported by a technical team with a significant number of years' experience with this unique process.

The process uses zircon sand for the mold, which when compared to conventional silica sand, provides greater accuracy and stability, leading to improved cast-in feature content and opportunities for reduced machining requirements. This allows design freedom to optimise weight and enhance features.

After the initial melting process, the molten aluminium is degassed using argon and stored under a nitrogen blanket to reduce and minimize the level of impurities. The metal is then drawn from the cleanest, mid-level sector of the tank using an electromagnetic launder system to virtually eliminate any risk of oxidation.

Using its own electromagnetic pump metal delivery system, molds are filled in a non-turbulent manner, minimizing defect formation and maximizing both casting quality and durability.

The density and thermal expansion coefficient of the zircon sand are very close to those of aluminium and this ensures minimal movement of the cores within the mold during the filling process.

The use of gentle thermal sand removal significantly reduces the risk of distortion, thus enhancing dimensional accuracy.

By adopting this approach, the first stage of the development process can often be eliminated, giving the opportunity for reduced costs and production lead times and bringing many advantages for the designer, machinist, and ultimately, the end user. New tooling techniques have also been adopted by our dedicated development team to further improve project efficiency.

Furthermore, MAGMASOFT® simulation software, specifically tailored to our patented casting process COSCAST™, enables early prediction of potential integrity issues and design for manufacture at the concept stage.

The resulting aluminium casting can be lighter than an equivalent part produced by other proprietary processes, leading to improved performance with reduced fuel consumption and emissions.

Benefits:

• Light weight, and high dimensional accuracy combined with structural and material integrity
• Manufactured using the COSCAST™ process developed to meet the exacting demands of modern applications
• MAGMASOFT® simulation software
• Extensive OEN experience with series volumes
• Low volume batch and niche production
• Prototyping services
• Series volume

X-Ray Monitoring	Zircon Sand Core