Best-In-Class
Multi Material Lightweight Vehicle Front Kick Down Rail Magna International, Troy, Michigan.
Material: Aluminum Aural 5S-T5 temper. Process: High pressure vacuum diecasting. Weight: 2.63 lbs. (1.195 kg). Dimensions: 16.4 x 25.9 x 27.8 in. (417
mm x 658 mm x 707 mm). Application: Structural automotive body component.
• The kick down rail is one of several structural cast compo- nents being developed through the Multi Materials Light- weight Vehicle (MMLV) Project launched in 2012 among Magna International, the U.S. Department of Energy and Ford Motor Co.
• Cast in alumiumum Aural 52, the diec asting integrates five steel stampings and is about 25% lighter. It lowers the weight from the base line vehicle from 1.6 to 1.2 kg per side.
• The structural casting acts as chassis reinforcement for the front structure and adds stiffness, torque load capacity and torsional rigidity to the MMLV body structure.
Best-In-Class Stalk Roll
Grede-Columbiana, Columbiana, Alabama
Material: Ductile iron 80-55-06. Process: Lost foam casting. Weight: 23 lbs. Dimensions: 22.6 x 4.6 in. (575 x 118 mm). Application: Assist in the separation and processing of corn stalk mate- rial during harvest.
• By utilizing the lost foam casting process, the stalk roll was able to be designed with thin walls, insets and complex geometry which led to the weight reduc- tion of about 1 lb.
• Holes in the casting were made without cores at no additional cost by adding a pin in the tool cavity for the foam pattern.
• The reduction of metal in the casting and material to be removed during machining resulted in overall cost savings. Due to the tooling complexity and flexibility of adding back-drafted features and removing mate- rial, the stalk roll’s shape is symmetrical.
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