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Potentials in die casting
Structural components to reduce body weight in cars is a hot topic in automotive, particularly with the growth in electric and hybrid cars. What are the challenges? Where are we going?
07-199-2018
To find out about the challenges and the way to go, we interviewed Hermann Roos, our Structural Process Manager, to share some insights with us.
Hermann: I have been working within the die-casting industry for more than 10 years. I completed my studies in Aalen in 2008 and started working for Bühler in the same year. After working in training, application technology and consulting, I am now responsible for the structural process within Bühler.
Hermann: Structural components are gaining importance in the automotive industry. At the moment they can mainly be found in high-end vehicles. But battery weights in electric vehicles and the additional electric motor in hybrid vehicles are a concern for manufacturers. They need to reduce weight for better range and efficiency. Structural components offer a good solution for weight reduction.
Hermann: Die cast structural components are in competition with alternative materials and processes – such as steel or aluminum panels. Therefore we need to work on the efficiency of the die-casting process in order to be able to produce more cost-efficiently and increase our competitiveness.
Hermann: In order to save costs, it is important to take into account the whole value chain. One starting point could be the reduction of the wall thickness. About 40 % of part costs arise from the material. Our calculations show that reducing wall thickness can lead to up to a 10 % reduction in the overall costs. But also the usage of secondary alloys and a process without heat treatment have potential for the future.
Hermann: For us it’s important to increase the competitiveness of structural components made in the die-casting process. Therefore we continuously work on detecting cost saving potential in the different process steps. Moreover, we are testing alternative production processes together with partners. With a global share of around 50 % on the market for structural components and over 100 installed structural cells, we are the market leader for the structural die-casting process. We therefore see it as our responsibility to further develop the process together with our customers and partners in the die casting industry.