2020 Die-Casting Competition shows innovative solutions
The ninth International Aluminium Die-Casting Competition was organised by Düsseldorf-based Gesamtverband der Aluminiumindustrie e. V. (GDA). It was run in partnership with the German Foundrymen’s Association (Bundesverband der Deutschen Gießerei-Industrie, BDG), the Swiss aluminium association and the non-ferrous metals trade association of the Austrian Economic Chambers (Fachverband Nichteisenmetalle in der Wirtschaftskammer Österreich).
Die-casting has been a successful industrial casting process for series or mass production of structural parts for decades. Die-casting foundries have become increasingly important as suppliers to automobile manufacturers, companies engaged in mechanical and plant engineering and other branches of industry, such as communications technology, the furniture industry and the electrical and electronics industries. The development of ever-newer die-cast components is advancing rapidly. Whether it be structural elements, parts for electric cars or intelligent components for conventional vehicles, attempts are being made everywhere to make use of the outstanding options that die-casting has to offer. Together with machine manufacturers, alloy suppliers and processing companies, die-casters are constantly pushing forward the limits of the process by means of innovations. It is remarkable what innovative solutions and components have been developed.
The International Aluminium Die-Casting Competition has been a successful platform for demonstrating the high standard of quality of aluminium die-casting for many years. The aim of the competition is to increase interest in the versatile material aluminium and to highlight innovative areas of use. The criteria for evaluating the castings submitted to the International Aluminium Die-Casting Competition 2020 were compatibility with the die-casting process and the resource-efficiency of the design.
A jury of experts from research and practice awarded prizes to the following six entries.
The winners are:
"Special Commendations":
Special Commendation: Housing components for electric-vehicle control device
Alupress AG, Brixen, Italy
Alloy: AISi12(Fe)a
Weight: 1 450 g
Dimensions: L 350 mm, W 175 mm, H 70 mm
This casting is receiving a special commendation for the savings of up to 30% on installation space and weight that result from the integration of a large number of functions. The casting has an intelligent liquid cooling system with a laser-welded housing cover. From a design point of view, this meant adapting the original design and reducing the mass locally. A significant reduction in cycle time could be achieved by the use of laser welding for joining. Further-more, the overall concept provided a cost-effective solution.
Special Commendation: String inverter
FBL Pressofusioni srl, Vobarno, Italy
Alloy: EN AC-46000
Dimensions Inner parts (2)
L 533 mm, W 386 mm, H 266 mm
Weight: 9 700 g / 9 600 g
Dimensions Outer parts (2)
L 705 x / 704 mm, W 527 x / 527 mm, H 150 / 150 mm
Weight: 12 000 g / 7 000 g
A four-piece string inverter with a large number of integrated functions and mounting options for the internal electrical components is also receiving a special commendation. The castings are characterised by deep ribs to cool the housing. The consistent method of developing the casting system with the aim of reducing porosity or distributing it to a non-critical area is also highly commendable.
The award-winning castings will be exhibited at EUROGUSS 2020 (14-16 January 2020) outside the venue for the Die Casting Congress (NCC Ost) and will also be on show this year at the ALUMINIUM trade fair in Düsseldorf (6-8 October 2020, Hall 13, Stand D49).