Award for FRECH for its use of the Vacural® die-casting process to manufacture complex lightweight components
Whilst developing an ultra-lightweight gearbox cover for the electric powertrain of a passenger car, FRECH implemented a new methodology. Using an improved Vacural® die-casting process, the quality of the casting was enhanced and an additional weight reduction of 34 per cent was achieved.
Quality improvement and weight reduction through innovative die-casting solutions
“I am delighted to hear that FRECH has received the ‘IMA Award of Excellence for Processes’. This award is a significant achievement and underlines the company’s innovative strength and expertise in the field of die-casting solutions, particularly in the context of electromobility. “The collaboration within the project consortium demonstrates how important partnerships are for the development of advanced technologies,” said Dr Thomas Franco, Chief Technology Officer at Oskar Frech GmbH + Co. KG. The project consortium developed a design methodology for ultra-lightweight gearbox covers for the electric powertrain of passenger cars.
This offers additional weight-saving potential of 15 to 35 per cent for load-bearing applications such as housings and covers through the use of magnesium. “By substituting aluminium with magnesium, an initial weight saving of 25 per cent was achieved for the gearbox cover compared with a reference component. Building on this, a further weight reduction of 34 per cent was achieved by using a structurally improved Vacural ® die-casting process from FRECH. “In addition to improving the casting quality, the total weight of the gearbox cover has been halved,” explains Dr Franco, highlighting the opportunities. Electrified drive concepts, comprising complex cast housings with integrated gearboxes and motors as well as a multitude of attached components, offer the foundry industry new fields of application.
“The Vacural ® die-casting process has proven ideal for the production of complex lightweight components in the development of lightweight structures within the context of electromobility. Whilst maintaining high casting quality, the weight reduction of the end product results in both significant material savings and a reduction in CO₂ emissions,” says Dr Franco.
Further information on the ‘IMA Award of Excellence’:
The ‘IMA Award of Excellence’ is presented annually by the International Magnesium Association (IMA). It recognises companies, innovative products and manufacturing technologies for the various applications of magnesium. The IMA Award is presented in six categories: automotive castings, commercial castings, processes, forged products, environmental responsibility and future technologies in the field of magnesium. The project consortium received the award in the ‘Processes’ category.
Further information: https://www.intlmag.org/page/showcase2024-process
More about the ‘InDrutec-E’ project:
The aim of the ‘InDrutec-E’ project (Innovation Leadership in Die-Casting Technologies for Electromobility) is to assume and further expand technological leadership in the field of die-casting light metal alloys through innovative developments, including for the electromobility sector. To this end, new innovations in materials and manufacturing processes – optimised for the changed requirements of the electric powertrain – are being developed, which are intended to enable lower component weight alongside reduced costs, lower CO2 emissions and improved component quality. For cost-effective and CO₂-reducing lightweight construction, several innovative technological approaches are available in the field of die-cast components, which have the potential to reduce weight by 15% to 35% in specific component areas of electric vehicles. As partners in the project, Robert Bosch GmbH, Oskar Frech GmbH + Co. KG and Gühring KG are working together with Aalen University and the DLR Institute of Vehicle Concepts (project lead) on the aforementioned technological developments. They are supported in this by the associated partners Andreas Stihl AG & Co. KG and EJOT GmbH & Co. KG.