Foundry Technology Aalen (GTA)

The die casting process is the fastest way from the liquid melt to the finished part. In the field (of) Foundry Technology at Aalen University of Applied Sciences, 3 die casting machines are available for teaching and research projects.

The foundry laboratory consists of; have three die casting machines for research work.

Current topics are

- Gas injection for hollow structures

- Salt cores for structural components

- CFRP-magnesium and aluminum die casting hybrid components

- Alloy development in the field (of) magnesium, aluminum and zinc alloys

- Process optimization through innovative sensor technology

- Ageing processes for zinc die-cast alloys

- Assynchronous rotors for electric machines made of pure copper

- Artificial intelligence for quality monitoring in die casting

Die casting in the foundry laboratory at Aalen University of Applied Sciences

Students in the foundry laboratory at the hot chamber machine from Frech

GDK750 Vacural - cold chamber die casting machine from Müller-Weingarten/Frech with 800 tons of clamping force

DAK 400 Frech Vacural - cold chamber die casting machine with 400 tons clamping force for aluminum and magnesium alloys

DAW 125E Frech - hot chamber machine for research in the field (of) zinc die casting

In the internship, work placement, practicum in gravity die casting, the technological properties of eutectic and hypoeutectic aluminum-silicon alloys are investigated using a casting spiral, among other things.

The different sand characterizations are determined in the sand laboratory. Analyses ranging from compressive strength and gas permeability to sieve analysis can be carried out.

It is impossible to imagine modern foundries without the topic of Simulation.

The foundry laboratory has 20 MAGMASOFT® work stations available for vocational training. All students ... in the Mechanical Engineering/Production and Management subject area as well as the masters/master's programmes TMM PEF and LBM can learn the basic use of MAGMASOFT® here.

Zeiss Metrotom1500 computer tomograph procured in 2018 from DFG, state and university funds

Pores and shrinkage porosities can be visualized three-dimensionally in the 3D computer tomograph.

Axial section through a cast component

Metallographic sections and material-specific properties can be determined in the laboratory / lab for materials testing.

Various testing devices are available to determine the characteristic values. These include a resonance pulsator.

The following can be tested

• creep strength
• tensile strength
• hardness
• Fatigue strength can be determined.

Clamping of a tensile specimen made of die-cast magnesium

Influence of electromobility on casting production 11.30 MBPDF

Influence of electromobility on casting production 23.00 MBPDF

Production of CFRP hybrid components from aluminum and magnesium die casting

CFRP die-cast hybrid components616 KBPDF

SmartPro cooperation network

Die-cast copper rotors for asynchronous motors

Funding by the AiF FH³ 1727x05

Copper rotors in die casting3.55 MBPDF

Salt cores and die-cast part

Salt cores in die casting857 KBPDF

Many plastic injection molded parts are produced using gas injection technology to create hollow parts.

Example: Daimler door handle

Possible application would be the injection (blowing out) of oil channels in die-cast oil filter housings

Media-conducting channels in die casting407 KBPDF

Gas injection on the way to industrial application1.35 MBPDF

Gas injection on the way to industrial application1.09 MBPDF

Gas injection in magnesium hot chamber0.91 MBPDF

Magnesium die casting with hollow structures using gas injection in the hot chamber process883 KBPDF

Using gas injection in HPDC679 KBPDF

Die-cast part produced using the gas injection process.

Funding by the Landesstiftung

Strength of aluminum castings after heat treatment476 KBPDF

in cooperation, cooperative venture, partnership, collaboration with AWT Bremen

Correlation between natural and artificial aging of zinc die casting alloys

Funding by the AiF

NADCA Best Paper Award2.86 MBPDF

Creep and Ageing of Zinc1.40 MBPDF

Ageing processes of zinc die casting alloys1.55 MBPDF

Ageing of Zinc Alloys2.52 MBPDF

Ageing Properties of Zinc Alloys105 KBPDF

Alternating Strength of Magnesium Die Casting Alloys

Endurance limit of die-cast magnesium alloys544 KBPDF

Endurance limit of die-cast magnesium alloys AM50hp and AZ91hp depending1.94 MBPDF

Funding by the DFG

Hypereutectic AlSi alloys4.97 MBPDF

Wear-stressed aluminum castings in die casting2.95 MBPDF

Project description14.31 KBPDF

Correlation of process parameters in high pressure die casting564 KBPDF

Cognitive system for reducing the scrap rate in die casting3.84 MBPDF

Link to the project homepage Link MUSIC

Project partnership: Funding by the AiF, FHProfund

Variable gate geometry in die casting656 KBPDF

Innovative venting unit for die casting molds

Project partnership: Funding by the AiF, Pro Inno

Publication on the project407 KBPDF

Funding by the BMBF

Project description54 KBPDF

Infiltration of coated freeze-casting preforms by innovative die casting processes

Joint project with the TU Karlsruhe.

Funding by the DFG

Infiltration of ceramic-reinforced die-cast components669 KBPDF

Funding by the EU in the 5th Framework Program