INDUSTRY NEWS/行業新聞
IMA 2014 Awards Highlight Advances in Magnesium Technology, Processes and Products
IMA 2014奖凸显镁工业技术、工艺和产品的进步 Te International Magnesium Association (IMA), Wauconda,
Ill., recognized advances in magnesium technology, products and processes in the 2014 Awards of Excellence during the 71st Annual World Magnesium Conference held in Munich, Germany, in June. Te IMA Awards of Excellence highlight how the magnesium indus- try is continually working to improve the manufacturing process and companies that provide innovative and improved products made from lightweight magnesium. Te Design Category of the awards includes subcategories for
cast and wrought products. Te Award of Excellence in the Design- Cast Product Automotive Category was presented to Georg Fischer GmbH & Co KG in Altenmarkt, Austria, for an oil conduit module used in the powertrain of the Porsche Panamera. Te part was pro- duced via the magnesium high-pressure die casting process developed with partner GF Automotive AG in Schaffhausen, Switzerland. Te oil conduct module is the first of its kind produced with creep
resistant magnesium alloy (MgAl4Re4), resulting in 1 kg of weight saving compared to the previous aluminum part. Te magnesium design features 100% cast-in oil ducts, and a finished cast-in sealing contour for the oil-water-heat exchanger. Te manufacturing process included casting, machining and assembly of the component. Te sup- plier delivered the module complete with oil-water-heat exchanger, oil filter, reduction piece and other small parts to their customer, Porsche. Te Award of Excellence in the Design-Cast Product Commer-
cial Category was presented to Christie Digital Systems in Kitchener, Ontario, Canada, for a light engine enclosure used in a projector. Te enclosure, which was originally a two-part component made using the Tixomold process, was redesigned as one-piece magnesium diecasting. Changing the design yielded a number of improvements and benefits, including a 40-percent reduction in cost, improved dimensional accuracy and weight savings, according to Rob Malarky, Engineering Project Manager at Chicago White Metal Casting, Inc. in Bensenville, Ill. Several challenges had to be met in order to redesign the enclo-
sure. Working closely with the customer, internal features that created undercuts were reviewed and redesigned, resulting in a design that was simpler and easier to manufacture. “Not only did you have a two-piece assembly, which is more expensive, but you also had the assembly di- mensional component to it,” said Malarky. Te two-piece assembly, he noted, could “give the customer issues when they are assembling their final product down the line.” By simplifying the two-piece
assembly into a one-piece die cast component, the customer saved money on components, shipping, and assembly time. Te 40% cost reduc- tion was achieved by eliminating the purchase of a second casting, die trim, additional machining and dowel pin insertions. Te redesigned component went from a 2.5 lb. two-piece assem- bly to a 2.3 lb. one-piece die cast part, achieving an 8% weight reduction for the part. ■
今年6月，国际镁工业协会（IMA）（伊利诺伊州
Wauconda），在德国慕尼黑举行的“第71届世界镁工 业论坛”上将“2014年度奖”的主题确定为：镁工业技 术、产品和工艺的进步。IMA“年度优秀奖”的评选展 现镁工业生产工艺的不断提高，表彰那些在创新和改进 轻质镁合金产品方面有突出表现的企业。 奖项的类别包括铸造和锻造产品，奥地利Altenmarkt
的Georg Fischer公司凭借为保时捷帕纳美拉的动力传动 系统设计的油管组件，获得了汽车类铸件设计“优秀奖” 。该部件是Georg Fischer公司通过与瑞士沙夫豪森的GF 汽车公司合作研发的镁合金压铸工艺生产出来的。 该油管组件是首个使用抗蠕变镁合金（MgAl4Re4） 生产的组件，与之前的铝合金件相比，重量减轻了1公 斤。油-水热交换器镁合金件的设计采用的是在浇注导油 管时，植入已铸好的密封的回路。组件的生产工艺包括 铸造、加工和组装。Georg Fischer为其客户保时捷公司 生产的全套组件包括油-水热交换器、滤油器、缩径管接 头和其他小部件。
商业类的铸件设计“优秀奖”授予了Christie数字系 统公司（加拿大安大略省Kitchener），该公司的获奖 作品是一款用于投影仪的轻型单机外壳。该外壳最初是 采用Thixomold工艺生产的由两个部分组成的部件， 后来经重新设计变成了单件的镁合金压铸件。据芝加 哥White Metal 铸造公司（伊利诺伊州本森维尔）的 工程项目经理Rob Malarky称，设计的改变带来了很多 优点，包括性能的改进，成本降低了40%、提高了尺 寸精度并减轻了重量。然而，外壳的重新设计面临着几 个方面的挑战。通过与客户密切合作，下部凹底的内部 结构经重新审视和设计，最终的设计更加简单且易于生 产。Malarky 说：“问题是不仅需要将这两个零件组装 起来成本较高，还需要将与之有关的部件组装起来。” 他指出，“在客户按生产线流程组装最终产品时，这两 个零件的组装会给客户带来难 题。”通过将两个零件的组装 简化为单件压铸件，为客户节 省了零件的运输费用和组装时 间。通过减少一个铸件、模 具的维修、额外的加工和定位 销，节约了40%的成本。重新 设计后的部件由两个零件组成 的重达2.5磅的铸件变成了一 个2.3磅的单件压铸件，重量 减轻了8%。 ■
September 2014
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 17
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