CPT International 4/2019

a
Nuremberg, Germany
14 –16.1.2020
b
International Trade Fair for Die Casting:
Technology, Processes, Products
Figure 7: Development
of a tubular cross member
incorporating a
ductile iron casting as
shaft with welded on
flanges made of steel.
a) welding concept, b)
compression welding of the parts using the MagnetArc process.
the analysis of material behaviour under different load cases.
Various weight-optimized series parts, such as the ductile iron
reinforced member for a driver‘s cabin (Figure 4) or a newly
designed suspension bracket made of the aluminium alloy
EN-AC-Al- Si10Mg T6 (Figure 5) testify to the practical usefulness
of the concepts.
Light-weight engineering by means of structural
welding
Structural welding (Figure 6) is used to join castings with formed
steel components. The most common methods are fusion
and compression welding. These welding techniques are
widely used in the manufacturing of differential cases with a
ring gear (Figure 7), which include a welded joint between
ductile cast iron and steel.
FUTURE
CASTING
IDEAS
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Bottom line
> By using the design flexibility of casting technology, components
of a much higher loadability can be designed
than – allegedly – achievable by an increase in material
strength.
> The application of methods of bionics are recommended
for castings only.
> Structural welding enhances the functionality and promotes
light-weighting by joining ductile iron castings and formed
steel components.
> Forging and casting are complementary forming processes
which give fresh impetus for new light-weight, highly
loadable and economically efficient structural components.
About Franken Guss
Franken Guss is a medium-sized company and, together with
Sachsen Guss in the German federal state of Saxony, part of
JORA Holding. The foundry has a more than 90-year-history in
Kitzingen, Germany.
The contents of this article have already been dealt with in
a paper presented at the IFU Congress NE-MU on 14/15 May
2019.
Dr.-Ing. Wolfgang Knothe, Development Iron Casting,
Franken Guss GmbH & Co.
Honorary sponsors
VDD Verband Deutscher
Druckgießereien, Düsseldorf
CEMAFON, Frankfurt am Main
We’ll be pleased to help you!
NürnbergMesse GmbH
T +49 9 11 86 06-49 16
visitorservice@nuernbergmesse.de
CASTING PLANT & TECHNOLOGY 4/2019 29