When sparks fly or red-hot metal flows into precise molds under enormous pressure, his heart beats faster: For 22 years, Professor Dr. Lothar Kallien has headed the foundry laboratory at Aalen University of Applied Sciences with as much passion as expertise. During this time, the materials engineer has developed the foundry laboratory into one of the largest academic die casting foundries in the whole of southern Germany, which regularly attracts experts and students from all over Germany. Thanks in particular to courses such as the Barbara Colloquium and the Foundry Colloquium, the Aalen foundry laboratory has developed into a "Mecca" especially for the die casting industry. Kallien is now retiring at the end of February: "It was a gift for me to be able to turn my hobby into my appointment funding for professors; appointment funds."
With ease
An ancient craft, combined with state-of-the-art high technology, robotics and materials science - foundry technology plays a key role in numerous branches of industry. Whether electromobility, renewable Energy or digitalization: innovative casting solutions are the backbone for many new technologies. They enable the production of components that can withstand extreme loads or are particularly light and efficient. Professor Lothar Kallien fishes the engine housing cover of a Fiat 500 Elektro off the shelf. "It used to weigh three kilos, now it only weighs one kilo," says Kallien, not without pride. Saving weight is particularly important for electric cars, as the batteries are comparatively heavy. "Lightweight yet stable die-cast components help to increase the range and efficiency of vehicles," explains the 66-year-old. This is why die casting with lightweight materials such as aluminum or magnesium is at the forefront of research activities, even though a wide range of casting techniques are used in the foundry laboratory.
Further development of the gas injection process
Kallien is particularly proud of the further development of the gas injection process. This involves injecting a gas into the molten metal during the die casting process. The gas ensures that hollow channels are created in the casting through which cooling media can flow in power electronics components. This keeps the casting stable, but makes it much lighter. Another focus is on multi-material lightweight construction, in which various regenerative materials such as wood and metals are combined in order to make the best possible use of their potential. "The 100% recyclability of casting alloys, combined with modern foundry technologies, is an important step towards greater Sustainability," emphasizes Kallien.
Old foundry family
You could almost say that a love of foundry technology runs through Professor Dr. Lothar Kallien's veins, as he comes from an old foundry family. "Grandfather, father, brother and father-in-law - all foundrymen. I never had the chance to take up an appointment for professors; appointment funds," laughs the Heidelberg native. As a child, he occasionally accompanied his father - owner of a foundry supplies company that his brother now runs - on his business trips. "Back then, I was even in Aalen from time to time when I went to SHW," recalls Kallien, who was passionate about tinkering with mopeds in his youth and "always felt like an engineer". And since the apple doesn't fall far from the tree, he studied metallurgy and materials engineering with a special field in foundry technology at RWTH Aachen after completing his Abitur, university entrance qualification.
"The first German space mission, Spacelab D1, strengthened my interest in research"
Kallien then went on to do a doctorate under Professor Dr. Peter R. Sahm, who was the academic coordinator of the first German space mission Spacelab D1 at the time. As Professor of Foundry Engineering at RWTH Aachen University, Sahm coordinated the multidisciplinary experiments in materials and life sciences. "That was an incredibly exciting and fascinating time, and also reinforced my great interest in research," enthuses Kallien. After his time at the Foundry Institute, his career began in 1988 with a spin-off from the Chair, the company MAGMA Gießereitechnologie GmbH. This was based on research work into the Simulation of casting processes - a groundbreaking technology at the time that revolutionized the development and optimization of cast parts. The academic idea resulted in the MAGMAsoft software, a product that is in demand worldwide and is now considered the industry standard.
Aalen University of Applied Sciences? "The best decision ever!"
After several years in the USA, where the father of three set up a branch of the company in Chicago, he returned to Aachen. "We had just finished building our house and my wife had thrown away all the boxes - that's when I was asked if I could imagine succeeding Professor Dr. Friedrich Klein, who had headed the foundry laboratory at Aalen University of Applied Sciences," says Kallien. He didn't have to think about it for long, and new moving boxes were purchased. "It was a 100 percent passport - and the best decision ever. I was really able to turn my hobby into an appointment for professors; that's not something you can take for granted," says Kallien with great gratitude. The cooperation, cooperative venture, partnership, collaboration with the students, seeing their potential and helping them develop, has also been a very enriching part of his working life.
Now the moving boxes are being packed again
"I also have to say a huge thank you to my Law partner Thomas Weidler, the best senior engineer of all time," says Kallien enthusiastically. Handing over the baton now is not easy for the passionate researcher - after all, there are always new things to discover in die casting. "But everything has its time, and you have to make room for younger people." He is particularly pleased that the foundry laboratory and production at Aalen University of Applied Sciences will continue with an endowed professorship. "After all, the laboratory / lab is brutally good with all the new die casting machines and our computer tomograph. Aalen has a unique selling point here," emphasizes Kallien. And who knows, maybe he'll drop in on one or two foundry Colloquiums in the future despite his retirement. But now it's time to pack his moving boxes again. They are heading back home. Since 2010, the Kalliens have had an old wine-growing farm near Landau, which has served as a vacation home all these years and will now become their "real" permanent residence.
