Best-In-Class
Liftgate—Inner Meridian Magnesium Products of America, Eaton Rapids, Mich.
Material: Magnesium. Process: Diecasting. Weight: 17.6 lbs. Dimensions: 54.3 x 51.8 in. Application: Automotive structure.
• The single piece magnesium casting achieved a more than 20% weight reduc- tion over a traditional steel liftgate and integrated six parts into one panel, the largest of its type in the world.
• The casting overcame several design challenges through local wall thickness addition and cast-in structural features. It provided increased packaging volume and fl exibility and eliminated secondary machining operations, seams and welds.
Best-In-Class
Four Cylinder Intake Manifold Eagle Aluminum Cast Products, Muskegon, Mich.
Material: A356 aluminum. Process: Green sand. Weight: 13 lbs. Dimensions: 17 x 10 x 7 in. Application: Automotive aftermarket part. Converted from: Sheet metal weldment.
MODERN CASTING / June 2010
• The high performance automotive aftermarket manifold was 50% less ex- pensive to manufacture than the sheet metal alternative and provided an engine performance boost.
• Intricate shell cores were used to produce the internal structures of the part (also known as a pressurized air delivery turbo charger), which is marketed by the customer as an upgrade on several major makes of automobile.
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