2020 Die-Casting Competition: prizes for innovative aluminium die-castings

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The winners of the International Aluminium Die-Casting Award 2020 have been announced. In all, four castings were awarded prizes at Euroguss 2020 in Nuremberg, while two others received special commendations.

The ninth International Aluminium Die-Casting Competition was organized by Düsseldorf-based Gesamtverband der Aluminiumindustrie (GDA). It was run in partnership with the German Foundrymen’s Association (BDG), the Swiss aluminium association (alu.ch) and the non-ferrous metals trade association of the Austrian Economic Chambers.

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:

1st Prize: Oil-coolant module
Hengst SE, Nordwalde, Germany
Alloy: AISi9Cu3(Fe), Weight: 8,655 g, Dimensions: L 443 mm, W 340 mm, H 195 mm

The first prize is being awarded for the consistent development methodology used from the design of the casting via the tool design through to the casting process, and which clearly has no taboos and is aimed at achieving optimum results. Decisive aspects were the complex geometry, with inner slides and the smallest possible demoulding drafts and low tolerances, which at the same time meets the most exacting demands for pressure tightness. The intensive tempering using all technical means available is particularly impressive.

2nd Prize: Housing for HV booster from Druckguss Westfalen

2nd Prize: Housing for HV booster
Druckguss Westfalen, Geseke, Germany
Alloy: EN AC-AISi10MnMg, Weight: 2,785 g, Dimensions: L 344 mm, W 365 mm, H 176 mm

The winner of the second prize is a die-casting with a large number of integrated functions that is subject to the most stringent sealing requirements because it has water-conducting cooling zones arranged next to zones with electricity at high voltage. Despite the thin wall thicknesses, high stiffness and dimensional accuracy were achieved using stiffening ribs. The low-copper aluminium alloy used ensures the part has high corrosion resistance and strength in the as-cast condition.

Two third prizes were granted to Alupress AG, Brixen, Italy (for the upper part of housing for dual-channel EBS), and to Nemak Slovakia in Žiar nad Hronom, Slovakia (for a battery housing).

Special Commendations were given to Alupress AG (for housing components for electric-vehicle control device) and to FBL Pressofusioni srl, Vobarno, Italy (for a string inverter)

The award-winning castings will be exhibited at Euroguss 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).

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