Under the leadership of the Institute of Vehicle Concepts of the German Aerospace Center (DLR), the project partners – Robert Bosch GmbH, Oskar Frech GmbH + Co. KG, Gühring KG, and Aalen University – supported by the associated partners Andreas Stihl AG & Co. KG, EJOT GmbH & Co. KG, and Rheinfelden Alloys, were able to achieve all set project goals and develop various components that can significantly contribute to technological leadership in die casting.
High Savings Potential Demonstrated
Using the example of a gearbox cover from the electric drive train, the technology was demonstrated in a production-like manner in both an aluminum and a magnesium variant and validated in tests.
Compared to a functionally identical aluminum reference component, the weight was reduced by 35 percent in the optimized aluminum variant and even by 51 percent in the magnesium variant. By using a specially developed secondary aluminum alloy, the CO2 emissions of the aluminum variant could be reduced by 86 percent. The emissions of the magnesium variant were also significantly reduced by 63 percent due to the lightweight effect and the use of green magnesium. The cost-saving potentials through the application of the technology components are considerable, ranging between 26 percent (aluminum) and 29.5 percent (magnesium).
IMA Award of Excellence
For their innovative development, the partners were awarded the Award of Excellence by the International Magnesium Association (IMA). The involved companies now aim to implement the project results in their products as soon as possible and make them accessible to the market.
