Zinc gives the mounts good wear resistance and tensile strength. Zinc under 6 oz/nonelectroplated Cast Products Inc., Norridge, Ill., created a new design for Gentex rearview mirror mounts used in Volvo Autos and SUVs. The die casting also provides attachment points for the instrument panel. The part reportedly gives the beam and steering column more stiffness as well as crash energy absorption. The part is cast in a 4,000-ton cold chamber IdraPrince DMC using a two-cavity die. The die cast magnesium part weighs half as much as the steel beam it replaces. Lunt Manufacturing Co., Schaumburg, Ill., created a die-cast cross-car beam for BMWs E-70. Zinc was previously used, but magnesium better dampens vibration and brings inherent EMI protection. The cast part is the assembly's backbone, holding fiber channels, clips, an EMI shield, hard drive, a locking mechanism and a pin connector. hard drives from a server, squelches and dampens vibrations from the disk drives, and protects against EMI. Magnesium under 0.5 lb Phillips Plastics Corp, Eau Claire, Wis., used a magnesium casting to make an assembly that injects and ejects 3.5-in. Compared to sand or semi-permanent mold casting, insert molded tubes are said to improve fluid flow efficiency, eliminate leaks, and reduce weight and cost. The process needs no special tooling or equipment. Each casting is produced from 380 aluminum with a minimum wall thickness of 3.0 mm. The tube assembly is made from welded together mandrel bent 304 stainless steel. The heat-treated aluminum shock towers have thin walls, yet give manufacturers the ability to weld and rivet the castings to other components.Ī patented insert molded tube technology from Metaldyne, Plymouth, Mich., was used to die cast a front engine module assembly (FEMA) for V-6 and V-8 engines. Contech used a new casting technology called High-Q-Cast to produce the lighter weight aluminum casting. With die casting, Contech, Portage, Mich., reduced the number of assembly components and dropped shock tower weight by 40%.
Qcast aluminum series#
The stainless steel insert molding weighs less than a stainless steel cast housing, without sacrificing performance or durability.Īluminum 1 to 10 lb Shock Towers for suspension mounting and alignment are traditionally made from a series of steel stampings welded together during vehicle body fabrication. It was cast in a two-cavity die with two stainless steel inserts per cavity and six core pulls.
The ERG positions and houses the valve actuator, maintains alignment, fixes the valve seats, and provides a sealing surface. Twin City Die Castings, Minneapolis, produced a one-piece exhaust gas recirculating (EGR) valve housing for car and truck diesel engines that has features usually done with multiple die and sand cast components. The parts were cast on a 2,000-ton Prince DMC (die casting machine) that puts a vertical shot into a verticle split die outfitted with horizontally moving die blocks. A two-cavity die and proprietary P2000 HVSC (high-vacuum squeeze casting) process let Contech meet Toyota's burst test and end cost targets. A computer component for electronic storage also received an award.Īluminum, Squeeze/Semi-Solid An innovative tooling design from Contech, Portage, Mich., made possible a large, complex housing for a rack and pinion steering gear used in Toyota Tundra and Sequoia trucks. The competition aim is to demonstrate the versatility, quality, innovation, and cost savings possible with aluminum, zinc, and magnesium die cast parts.Īccording to NADCA, several winning components are breakthroughs in casting because of their reduced weight - a significant factor in automobile engineering. The North American Die Casting Association (NADCA), Wheeling, Ill., handed out top honors to automotive OEMs for parts that exemplified performance and fuel economy.
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