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11/16/2023
Transformation of the drives
Die casting products
Report
Aluminium housing for electric drive topology
The car manufacturer BMW Group is casting an aluminium housing for the electric drive in its light metal foundry in Landshut. Series production is planned. The manufacturer expects injector casting to increase production capacity for the cast component to up to 800,000 units per year.
The car manufacturer is investing more than 200 million euros in the expansion of the Landshut light metal foundry in order to increase production of the central housing. The cast component for the electric drive topology will combine the electric motor, gearbox and inverter.
(from left) Karl Bauer, Head of Production Die Casting, Lost Foam and Injector Casting, with the guests of honour and Site and Foundry Manager Stefan Kasperowski, as well as Works Council Chairman Bernhard Ebner in front of the first castings of the new construction stage.Electromobility through injector casting
The quality requirements and geometry of the central housing for the electric drive require a new casting technology: Injector Casting (ICA). The automotive manufacturer presented the process at EUROGUSS 2022 in cooperation with the German Foundry Industry Association (BDG). The process utilizes the advantages of gravity casting and low-pressure casting and is intended to enable industrial series production in light metal foundries.Injector casting enables a finer microstructure and improves the mechanical properties of the cast part. It also shortens the cycle time, as the material solidifies from the base plate during the filling process.
A lower moulding temperature reduces energy consumption and thus lowers CO2 emissions. The process also requires less circulation material, as filling with the injector eliminates the need for an additional sprue system. As a result, the foundry saves up to 40 per cent of the melt.
The light metal foundry in Landshut won the Automotive Lean Production Award in the ‘Component Supplier’ category in November 2023. Sustainability, digitalization, innovation and process excellence are evaluated.
BMW Injector Casting Process - Innovative ingate system for gravity casting
