2018-05-02_CS_Produktflyer_EN
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GF Casting Solutions<br />
Innovative<br />
Products<br />
for you<br />
Innovative Products for you<br />
1<br />
<strong>EN</strong>
Worldwide<br />
for you<br />
SWITZERLAND<br />
GERMANY<br />
01 Biedenkopf Tooling<br />
<strong>02</strong> Leipzig Iron Casting<br />
03 Mettmann Iron Casting<br />
04 Munich Sales Office<br />
<strong>05</strong> Singen Iron Casting<br />
06 Werdohl High-Pressure<br />
Die-Casting<br />
07 Wolfsburg Sales Office<br />
SOUTH KOREA<br />
01 Seoul Sales Office<br />
Weight reduction<br />
2<br />
Passenger cars<br />
16<br />
Body & Structure 17<br />
E-Mobility 37<br />
Powertrain 40<br />
Chassis 55<br />
USA<br />
01 Grede LLC Cooperation<br />
<strong>02</strong> Mills River (NC) GF Linamar<br />
High-Pressure Die-Casting<br />
<br />
01 Schaffhausen Headquarter,<br />
R&D<br />
<strong>02</strong> Novazzano GF Precicast<br />
Investment Casting<br />
03 Novazzano GF Precicast<br />
Ceramic Cores<br />
04 Stabio GF Precicast<br />
3D Metal Printing, Additive<br />
Manufacturing<br />
ITALY<br />
ROMANIA<br />
01 Arad GF Precicast Finishing<br />
<strong>02</strong> Pitești High-Pressure Die-Casting<br />
03 Scornicești High-Pressure Die-Casting<br />
AUSTRIA<br />
01 Lecco Sales Office 01 Altenmarkt High-Pressure<br />
Die-Casting<br />
<strong>02</strong> Herzogenburg Iron Casting<br />
03 Herzogenburg High-Pressure<br />
Die-Casting<br />
CHINA<br />
JAPAN<br />
01 Riken Cooperation<br />
<strong>02</strong> Tokyo Sales Office<br />
01 Kunshan Iron Casting<br />
<strong>02</strong> Suzhou High-Pressure<br />
Die-Casting, Tooling<br />
Trucks<br />
60<br />
Powertrain 61<br />
Frame 65<br />
Industrial Applications<br />
76<br />
2 Innovative Products for you Innovative Products for you 3
Solutions in Bionic Design<br />
weight reduction<br />
Steering Knuckle<br />
weight reduction<br />
Customer<br />
Study GF Casting Solutions<br />
Process<br />
Iron sandcasting<br />
Material SiboDur 700<br />
Weight<br />
3.0 kg<br />
-26 %<br />
Your Advantage<br />
• Twisted ABS sensor (no sharp edges at the bore)<br />
• Free-standing wheel bearing slugs<br />
• Preformed water drain, reduced machining at the outer seal of the wheel bearing<br />
• Integrated attachment points<br />
• Attachments reduced to minimum size<br />
• Wheel bearing bores with optimal twist angle<br />
• Breakthrough at the supporting joints realizable through direct transmission of<br />
forces<br />
-17 %<br />
Bionic design<br />
Optimized structure, reduced machining<br />
effort, high-strength material, optimization<br />
of attachment points<br />
Optimized bionic design<br />
Optimized design with damper clamps<br />
(damper integration without core)<br />
4 Innovative Products for you Innovative Products for you 5
Lightweight Design with<br />
Functional Integration<br />
weight reduction<br />
Shock Tower<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
Audi A6/A7<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
4.3 kg<br />
Casting, punching, heat treatment,<br />
grinding, machining, assembling<br />
-45 %<br />
Substitution of sheet<br />
metal<br />
Your Advantage<br />
• Low tolerances through machining of attachment points<br />
• Through heat treatment the required crash performance is obtained<br />
• Integration of attachment points for cables and assemblies<br />
• Ten sheet metal parts substituted with one casting<br />
6 Innovative Products for you Innovative Products for you 7
Advantage in Casting<br />
weight reduction<br />
Inner Door Frame<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Maserati<br />
Quattroporte/Ghibli<br />
Aluminum high-pressure die-casting<br />
AlMg5Si2Mn<br />
5.5 kg<br />
Casting, punching, laser cutting,<br />
grinding, conversion coated<br />
-17 %<br />
Substitution of sheet<br />
metal<br />
Lighter than its sheet<br />
metal predecessor with<br />
high integration of<br />
functions<br />
Your Advantage<br />
• Integration of functions and weight reduction<br />
• Reduction of several components<br />
8 Innovative Products for you Innovative Products for you 9
Light Materials<br />
weight reduction<br />
Front Cover<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Porsche<br />
Panamera/Cayenne/Macan<br />
Magnesium high-pressure die-casting<br />
MgAl4RE4Mn<br />
2.1 kg<br />
Casting, punching,<br />
machining, assembling<br />
-45 %<br />
Material know-how<br />
Front Cover in<br />
magnesium - nearly<br />
half the weight than<br />
its predecessor in<br />
aluminum<br />
Your Advantage<br />
Magnesium<br />
• Component for engines in lightweight design<br />
• Creep resistant magnesium alloy<br />
• Winner IMA Award “Casting Design Automotive”<br />
Aluminum<br />
10 Innovative Products for you Innovative Products for you 11
Our Know-how in Materials<br />
weight reduction<br />
Oil Conduit Module<br />
Customer<br />
Porsche<br />
Vehicle<br />
Panamera/Cayenne/Macan<br />
Process<br />
Magnesium high-pressure die-casting<br />
Material<br />
MgAl4REMn<br />
Weight<br />
4.6 kg<br />
Value Chain<br />
Casting, machining, assembling<br />
-24 %<br />
Oil conduit module in<br />
magnesium<br />
Lighter than its predecessor<br />
in aluminum<br />
Your Advantage<br />
Magnesium<br />
• Component for engines in lightweight design<br />
• First Oil Conduit Module with satisfactory creep resistance in Magnesium<br />
• Winner IMA Award “Casting Design Automotive”<br />
Aluminum<br />
12 Innovative Products for you Innovative Products for you 13
Lightweight in Trucks<br />
weight reduction<br />
Differential Housing<br />
Customer<br />
DAF<br />
Vehicle<br />
XF<br />
Process<br />
Iron sandcasting<br />
Material GJS 400-17<br />
Weight<br />
55.5 kg<br />
Value Chain<br />
Casting<br />
-18 %<br />
Functional integration<br />
Lighter than its predecessor<br />
with high integration<br />
of functions<br />
Your Advantage<br />
• Weight reduction due to bionic design with high integration of functions<br />
14 Innovative Products for you Innovative Products for you 15
Lighter in Casting<br />
weight reduction<br />
Cross Beam<br />
Customer<br />
ZF Lemförder<br />
Vehicle<br />
DAF XF<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-14<br />
Weight<br />
28.0 kg<br />
Value Chain<br />
Casting<br />
-15 %<br />
One-piece casting<br />
Lighter than its predecessor<br />
with three parts in<br />
forged construction<br />
Your Advantage<br />
• Weight reduction due to bionic design with high integration of functions<br />
• One-piece casting, replaced forged-iron construction<br />
16 Innovative Products for you Innovative Products for you 17
Passenger cars<br />
Body & Structure<br />
Rear Door Frame<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Daimler<br />
C-Class<br />
Aluminum high-pressure die-casting<br />
AlSi10Mg<br />
5.4 kg<br />
Casting, punching, heat treatment, laser cutting,<br />
assembling, flattening, polishing<br />
Your Advantage<br />
• One of the largest die-castings in body & structure parts<br />
• Dimensions: 130x90x60 cm<br />
• High-precision laser-cutting<br />
• Winner NADCA Award<br />
18 Innovative Products for you Innovative Products for you 19
Body & Structure<br />
Door Frame<br />
Upper Door Frame<br />
Customer<br />
Porsche<br />
Vehicle 911<br />
Process<br />
Aluminum high-pressure die-casting<br />
Material<br />
AlMg5Si2Mn<br />
Weight<br />
4.2 kg<br />
Value Chain<br />
Casting, machining, laser-cutting,<br />
coating, assembling<br />
Customer<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Electric Vehicle Manufacturer<br />
Magnesium high-pressure die-casting<br />
AM50<br />
2.9 kg<br />
Casting, punching, mechanical<br />
machining, e-coating, assembling<br />
Your Advantage<br />
Your Advantage<br />
• Maximum integration of functions<br />
• Winner IMA Award “Casting Design Automotive”<br />
20 Innovative Products for you Innovative Products for you 21
Body & Structure<br />
Hinge Support<br />
Convertible Roof Top<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Lamborghini/Audi<br />
Huracán/R8<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
1.2 kg<br />
Casting, punching, heat treatment,<br />
machining, coating<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Magna CTS<br />
Opel Cascada Cabrio<br />
Magnesium high-pressure die-casting<br />
AM50 HP<br />
2.2 kg<br />
Casting, trimming, coating<br />
Your Advantage<br />
Your Advantage<br />
• Minimum wall thikness of 1.4 mm<br />
• Very limited size tolerances<br />
• Minimum wall thickness of 1.2 mm<br />
• No additional machining needed<br />
• High integration of functions<br />
• All 37 bore-holes and all cut outs are casted and<br />
laser-trimmed<br />
• Winner IMA Award “Casting Design Automotive”<br />
22 Innovative Products for you Innovative Products for you 23
Body & Structure<br />
Seat Frame<br />
Safety Belt Spool<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Lear<br />
Mercedes-Benz SLK<br />
Magnesium high-pressure die-casting<br />
MgAl5Mn<br />
2.0 kg<br />
Casting, punching, shot-blasting,<br />
deburring<br />
Customer<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Takata<br />
Aluminum high-pressure die-casting<br />
AlMg5Si2Mn<br />
0.1 kg<br />
Casting, trimming, machining<br />
Your Advantage<br />
Your Advantage<br />
• One-piece design with increased functional integration compared<br />
to its predecessor<br />
• Crash characteristics<br />
• Winner IMA Award “Casting Design Automotive”<br />
• Multi-cavity casting tool for cost efficiency<br />
• Increased strength results<br />
• Reduced machining effort<br />
• Dedicated materials and surface treatments on casting tool<br />
reducing wearing effect<br />
24 Innovative Products for you Innovative Products for you 25
Body & Structure<br />
Cross Car Beam<br />
Instrument Panel Beam<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Jaguar, Land Rover<br />
Range Rover/Range Rover Sport/Discovery<br />
Magnesium high-pressure die-casting<br />
AM60<br />
6.0 kg<br />
Casting, machining<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Continental VDO<br />
Smart fortwo<br />
Magnesium high-pressure die-casting<br />
MgAl5Mn<br />
2.4 kg<br />
Casting, punching, deburring<br />
Your Advantage<br />
Your Advantage<br />
• A lot of casted features<br />
• Machining content is reduced to minimum<br />
• One piece design with high integration of function in<br />
lightweight design<br />
• Extremely thin ribs and walls<br />
• Winner IMA Award “Casting Design Automotive”<br />
26 Innovative Products for you Innovative Products for you 27
Body & Structure<br />
Front Center Console<br />
Rear Center Console<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
A8 (PL65)<br />
Magnesium high-pressure die-casting<br />
MgAl5Mn (AM50)<br />
2.48 kg<br />
Casting, punching<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
A8 (PL65)<br />
Magnesium high-pressure die-casting<br />
MgAl5Mn (AM50)<br />
2.14 kg<br />
Casting, punching<br />
Your Advantage<br />
Your Advantage<br />
• No machining, only punched<br />
• 3 sliders<br />
• Integration of all fixing points (snap nuts)<br />
• High stiffness<br />
• Strong development support by GF Casting Solutions<br />
• Integrated connection to rear center console<br />
• No machining, only punched<br />
• 2 sliders<br />
• Integration of all fixing points (snap nuts)<br />
• High stiffness<br />
• Strong development support by GF Casting Solutions<br />
• Integrated connection to front center console<br />
28 Innovative Products for you Innovative Products for you 29
Body & Structure<br />
Center Console<br />
Front End Carrier<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Magna Intier<br />
Porsche Cayenne<br />
Magnesium high-pressure die-casting<br />
MgAl5Mn<br />
2.0 kg<br />
Casting, punching, shot-blasting<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Jaguar Land Rover<br />
Range Rover L4<strong>05</strong><br />
Magnesium high-pressure die-casting<br />
AM60<br />
5.9 kg<br />
Finished part<br />
Your Advantage<br />
• High integration of functions<br />
• Near net shape die-casting without machining<br />
Your Advantage<br />
• Component length over 170 cm<br />
30 Innovative Products for you Innovative Products for you 31
Body & Structure<br />
Shock Tower Support<br />
Shock Tower<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
A8<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
1.8 kg<br />
Casting, heat treatment,<br />
machining, assembling<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Rolls Royce<br />
Phantom/Cullinan<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg T6<br />
6.9 kg<br />
Casting, punching,<br />
heat treatment, machining<br />
Your Advantage<br />
Your Advantage<br />
• High cost reduction due to integration of functions<br />
• Low tolerances by machining the attachment points<br />
• Very high stiffness<br />
• High functional integration through one piece design<br />
combined with sheet metal design<br />
• Strong development support by GF Casting Solutions<br />
32 Innovative Products for you Innovative Products for you 33
Body & Structure<br />
Shock Tower<br />
Shock Tower<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
BMW<br />
7er/5er GT<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
4.5 kg<br />
Casting, punching, heat treatment,<br />
machining, laser-cutting, e-coating<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Volvo Car Corporation<br />
XC90/XC60/V90/S90<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
4.3 kg<br />
Casting, heat treatment, machining,<br />
assembling, coating<br />
Your Advantage<br />
Your Advantage<br />
• High functional integration<br />
• Lightweight design in aluminum HPDC for passenger cars in the luxury<br />
class<br />
• High functional integration through one-piece design compared<br />
to sheet-metal assembly<br />
34 Innovative Products for you Innovative Products for you 35
Body & Structure<br />
Tank Frame<br />
Tank Cap<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Magna<br />
BMW 7er PHEV<br />
Aluminum high-pressure die-casting<br />
AlSi10MgMn<br />
4.0 kg<br />
Casting, punching, heat tretment,<br />
grinding, machining, e-coating<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Magna<br />
BMW 7er PHEV<br />
Aluminum high-pressure die-casting<br />
AlSi10MgMn<br />
6.4 kg<br />
Casting, punching, heat tretment, grinding,<br />
machining<br />
Your Advantage<br />
Your Advantage<br />
• High demands on size accuracy as well as mechanical<br />
characteristics<br />
• Value chain including machining and e-coating covered<br />
by GF Casting Solutions<br />
• High demands on size accuracy as well as mechanical<br />
characteristics<br />
• Whole value chain including machining covered by GF<br />
Casting Solutions<br />
36 Innovative Products for you Innovative Products for you 37
Body & Structure<br />
E-Mobility<br />
Door Sill Frame Member<br />
Battery Housing<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
A8<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
10.4 kg<br />
Casting, punching, machining, assembling<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Panasonic<br />
VW Golf GTE/Audi A3 e-tron<br />
Aluminum high-pressure die-casting<br />
AlMg5Si2Mn<br />
16.7 kg<br />
Casting, punching, machining, assembling<br />
Your Advantage<br />
Your Advantage<br />
• Structure component made by a big die-casting machine<br />
with a high degree of vertical integration<br />
• High integration of functions in one large component<br />
38 Innovative Products for you Innovative Products for you Quelle:<br />
39 Audi
E-Mobility<br />
Battery Housing<br />
Battery Housing<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
BMW<br />
BMW X5 xDrive40e<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
9.2 kg<br />
Casting, punching, grinding, assembling, checking<br />
density, washing<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Volkswagen<br />
Passat GTE<br />
Aluminum high-pressure die-casting<br />
AlSi10MnMg<br />
16.5 kg<br />
Casting, machining, heat treatment,<br />
cleaning, assembling, checking density<br />
Your Advantage<br />
Your Advantage<br />
• Finished casted component without machining<br />
• Realisation of high requirements regarding tolerance,<br />
residual dirt etc.<br />
• Runner-up in the international high-pressure die-casting<br />
competition<br />
• High added value<br />
40 Innovative Products for you Innovative Products for you 41<br />
Source: BMW
Powertrain<br />
Rear Axle Housing<br />
Gearbox Housing<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Daimler<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
<strong>EN</strong>-AC46000<br />
5,6 kg<br />
Casting, coating<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Volkswagen<br />
Golf/Passat<br />
Magnesium high-pressure die-casting<br />
MgAl9Zn1<br />
6.8 kg<br />
Casting, punching<br />
Your Advantage<br />
Your Advantage<br />
• Die-casting tool with collapsible core (back draft)<br />
• Cast-in insert (<strong>EN</strong>-GJS-400-15)<br />
• Lightweight housing in magnesium<br />
42 Innovative Products for you Innovative Products for you 43
Powertrain<br />
Intermediate Housing<br />
Transmission Housing<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
7.<strong>05</strong> kg<br />
Casting, punching, shot-blasting,<br />
machining<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
ZF<br />
Volkswagen Amarok<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
15.2 kg<br />
Casting, punching,<br />
shot-blasting, machining<br />
Your Advantage<br />
Your Advantage<br />
• Component with high density requirement<br />
• Cast-in 3D-bended steel tubes<br />
• Complex machining<br />
44 Innovative Products for you Innovative Products for you 45
Powertrain<br />
Converter Housing<br />
Engine Block<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
ZF<br />
Audi Quattro, 8-speed-automatic<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
9.8 kg<br />
Casting, punching, machining<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Volkswagen/Skoda<br />
Diverse, 1.4l gasoline engines<br />
Aluminum high-pressure die-casting<br />
Al-Si9Cu3(Fe)<br />
18.9 kg<br />
Casting,punching, T5-heat treatment,<br />
pre-machining<br />
Your Advantage<br />
Your Advantage<br />
• High-precision component<br />
• Integrated grey iron bushings<br />
• Squeezing at all crankshaft bearings<br />
• Vacuum assisted high-pressure die-casting<br />
46 Innovative Products for you Innovative Products for you 47
Powertrain<br />
Engine Block<br />
Engine Block<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
JAC<br />
AO<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
16.4 kg<br />
Casting, machining<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
PSA<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
20.5 kg<br />
Casting, pre-machining (Cubing)<br />
Your Advantage<br />
Your Advantage<br />
• Complex casting process<br />
• Downsizing<br />
• Open-deck design<br />
• Integrated (casted-in) grey-iron cast liners<br />
• Integrated water-pump housing<br />
48 Innovative Products for you Innovative Products for you 49
Powertrain<br />
Oilpan Cover<br />
Drive End Shield<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Audi<br />
Audi RS8/R8<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3(FE)<br />
6.7 kg<br />
Casting, punching,<br />
cleaning, x-ray<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Bosch<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3(Fe)<br />
0.47 kg<br />
Casting, trimming, shot-blasting,<br />
machining, assembling<br />
Your Advantage<br />
• Ready-to-mount component<br />
• Die-casting tool with Flex concept for equipments’ costs<br />
reduction<br />
• CNC machining (VS transfer) for higher production flexibility<br />
and reduction of set-up time<br />
50 Innovative Products for you Innovative Products for you 51
Powertrain<br />
Turbocharger Housing<br />
Bedplate<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
BorgWarner<br />
BMW Engines 740 D<br />
Iron sandcasting<br />
SiMo1000<br />
4.1 kg<br />
Casting<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
JAC<br />
AO<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
16.4 kg<br />
Casting, machining<br />
Your Advantage<br />
Your Advantage<br />
• Weight reduction per kg including cost reduction<br />
• Range of application up to 900°C<br />
• Complex casting process<br />
• Downsizing<br />
52 Innovative Products for you Innovative Products for you 53
Powertrain<br />
Differential Housing<br />
Customer<br />
BMW<br />
Vehicle<br />
3 series/i3<br />
Process<br />
Iron sandcasting<br />
Material GJS 600-3<br />
Weight<br />
3.4 kg<br />
Value Chain<br />
Casting, machining<br />
Crankshaft<br />
Customer<br />
GM<br />
Vehicle<br />
Opel<br />
Process<br />
Iron sandcasting<br />
Material GJS 700-2<br />
Weight<br />
10.0 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Substitution of steel forging<br />
• 12% weight reduction thanks to hollow-casted design<br />
54 Innovative Products for you Innovative Products for you 55
Powertrain<br />
Chassis<br />
Exhaust Manifold<br />
Steering Knuckle<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
BMW<br />
6 Cyl.-diesel engines<br />
Iron sandcasting<br />
SiMo1000<br />
4.4 kg<br />
Casting, machining<br />
Customer<br />
Volkswagen<br />
Vehicle<br />
MQB<br />
Process<br />
Iron sandcasting<br />
Material GJS 450-10<br />
Weight<br />
3.9 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
Your Advantage<br />
• Material innovation with SiMo 1000<br />
• Excellent scaling characteristics<br />
• High temperature resistance<br />
• Weight reduction through bionic design<br />
• Cost-effective material<br />
• Easy machinability<br />
56 Innovative Products for you Innovative Products for you 57
Chassis<br />
Steering Knuckle<br />
Control Arm<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Hyundai/Kia<br />
Hyundai ix35/Kia Sportage<br />
Iron sandcasting<br />
<strong>EN</strong>-GJS-500<br />
5.6 kg<br />
Casting<br />
Customer<br />
Volkswagen<br />
Vehicle<br />
Touran/SuperB/Tiguan<br />
Process<br />
Iron sandcasting<br />
Material SiboDur 450-17<br />
Weight<br />
4.6 kg<br />
Value Chain<br />
Casting, machining<br />
Your Advantage<br />
• Bionic design with high-strength SiboDur material<br />
58 Innovative Products for you Innovative Products for you 59
Chassis<br />
Formula Student<br />
Wheel Carrier<br />
Customer<br />
Volkswagen<br />
Vehicle<br />
MQB<br />
Process<br />
Iron sandcasting<br />
Material SiboDur 700<br />
Weight<br />
3.8 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• 31 % weight reduction through bionic design<br />
and material innovation<br />
• High-strength material, integrated bearing<br />
Rear Frame<br />
KA-RaceIng KIT Karlsruhe, Season 2013 – Joint development<br />
and casting with GF Casting Solutions in the R&D Lab<br />
in Schaffhausen<br />
Wheel Carrier<br />
Team AMZ Racing ETH Zürich<br />
Season 2013/Season 2014<br />
Innovative lightweight design with integrated planetary gear<br />
fore-drive<br />
Developed, produced and tested with GF Casting Solutions in<br />
the GF R&D Lab in Schaffhausen<br />
World record in speed from 0-100 km/h in 1.513 seconds<br />
60 Innovative Products for you Innovative Products for you 61
Trucks<br />
Powertrain<br />
Exhaust Manifold (4 parts)<br />
Customer<br />
DAF<br />
Vehicle XF MX11 Motor EU 6<br />
Material<br />
SiMo4.5-1<br />
Process<br />
Iron sandcasting<br />
Weight<br />
16.0 kg<br />
Value Chain<br />
Casting, annealing, machining,<br />
isolating, assembling<br />
Your Advantage<br />
• Ready-to-mount solution<br />
• High scaling resistance<br />
62 Innovative Products for you Innovative Products for you 63
Powertrain<br />
Transmission Housing<br />
Transmission Housing<br />
Customer<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Volvo Trucks<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
40.6 kg<br />
Casting, punching, shot-blasting<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
ZF<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
28.3 kg<br />
Casting<br />
Your Advantage<br />
Your Advantage<br />
• Very high level of casting weight<br />
• Pressure density and size of the component<br />
• Large-size component produced with high quality standards<br />
64 Innovative Products for you Innovative Products for you 65
Powertrain<br />
Frame<br />
Transmission Housing<br />
Steering Knuckle Hydrodrive<br />
Customer<br />
Vehicle<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
ZF<br />
Iveco<br />
Aluminum high-pressure die-casting<br />
Al-Si9Cu3(Fe)<br />
12.0 kg<br />
Casting, punching, machining<br />
Customer<br />
Renault<br />
Vehicle<br />
Renault Premium Lander OpitTrack<br />
Process<br />
Iron sandcasting<br />
Material GJS 700<br />
Weight<br />
33.1 kg<br />
Value Chain<br />
Casting, machining, hardening<br />
Your Advantage<br />
Your Advantage<br />
• Integrated steel tubes<br />
• High-precision machining<br />
• Integrated steel tubes for hydraulic oil circuit<br />
• Inductively hardened<br />
• Rolled transition radius<br />
66 Innovative Products for you Innovative Products for you 67
Frame<br />
Brake Calliper<br />
Customer<br />
Knorr Bremse<br />
Vehicle<br />
Diverse<br />
Process<br />
Iron sandcasting<br />
Material GJS 600-6<br />
Weight<br />
22.0 kg<br />
Value Chain<br />
Casting<br />
Console<br />
Customer<br />
Daimler<br />
Vehicle<br />
Actros/Axor/Arocs/Antos<br />
Process<br />
Iron sandcasting<br />
Material GJS 450-18<br />
Weight<br />
9.8 kg<br />
Value Chain<br />
Casting, machining<br />
Your Advantage<br />
• Complex casting with high-strength requirements<br />
Your Advantage<br />
• Winner of the NEWCAST Award for the best<br />
substitution of another process with casting<br />
• Weight and cost reduction<br />
• Efficient machining<br />
68 Innovative Products for you Innovative Products for you 69
Frame<br />
Control Arm<br />
Customer<br />
ZF Lemförder<br />
Vehicle<br />
MAN<br />
Process<br />
Iron sandcasting<br />
Material ADI 1000-5<br />
Weight<br />
38.0 kg<br />
Value Chain<br />
Casting, heat treatment<br />
Frame Support<br />
Customer<br />
MAN<br />
Vehicle<br />
Diverse<br />
Process<br />
Iron sandcasting<br />
Material GJS 400-15<br />
Weight<br />
36.0 kg<br />
Value Chain<br />
Casting, machining, coating<br />
Your Advantage<br />
• 21 kg weight reduction through substitution of steel forging<br />
Your Advantage<br />
• High integration of functions<br />
70 Innovative Products for you Innovative Products for you 71
Frame<br />
Bionic Wheel Hub<br />
Customer<br />
Study GF Casting Solutions<br />
Vehicle<br />
Truck Rear Axle 13t<br />
Process<br />
Iron sandcasting<br />
Material <strong>EN</strong>-GJS 600-3<br />
Weight<br />
33.3 kg<br />
Wheel Hub<br />
Customer<br />
DAF<br />
Vehicle<br />
F1<strong>05</strong><br />
Process<br />
Iron sandcasting<br />
Material GJS 600-3<br />
Weight<br />
27.9 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Weight reduction of 4.8 kg due to bionic design<br />
• Improved air flow for brake cooling function<br />
• Optimized side force stiffness<br />
Your Advantage<br />
• Integrated brake attachment<br />
• Winner of the NEWCAST Award<br />
72 Innovative Products for you Innovative Products for you 73
Frame<br />
Air Suspension Bracket<br />
Customer<br />
Daimler<br />
Vehicle<br />
Actros<br />
Process<br />
Iron sandcasting<br />
Material SiboDur 700<br />
Weight<br />
28.4 kg<br />
Value Chain<br />
Casting, machining<br />
Middle Control Arm Support<br />
Customer<br />
Daimler<br />
Vehicle<br />
Actros<br />
Process<br />
Iron sandcasting<br />
Material GJS 600-3<br />
Weight<br />
97.0 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Weight optimization through high-strength iron<br />
material SiboDur<br />
Your Advantage<br />
• Weight optimization at the middle bearing for the<br />
leaf spring with flange bushing<br />
74 Innovative Products for you Innovative Products for you 75
Frame<br />
Control Arm Support<br />
Customer<br />
Daimler<br />
Vehicle<br />
Actros<br />
Process<br />
Iron sandcasting<br />
Material GJS 600-3<br />
Weight<br />
31.2 kg<br />
Value Chain<br />
Casting, machining<br />
Control Arm Support<br />
Customer<br />
MAN<br />
Vehicle<br />
Diverse<br />
Process<br />
Iron sandcasting<br />
Material SiboDur 700<br />
Weight<br />
28.0 kg<br />
Value Chain<br />
Casting, machining, coating<br />
Your Advantage<br />
• Integrated function for axle guidance and air-suspension mounting<br />
Your Advantage<br />
• 13 % Weight reduction through substitution of forged steel<br />
76 Innovative Products for you Innovative Products for you 77
Industrial Applications<br />
Converter Housing<br />
Application<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Diverse<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3<br />
15.8 kg<br />
Casting, punching,<br />
clipping, machining<br />
Your Advantage<br />
• High integration of functions<br />
78 Innovative Products for you Innovative Products for you 79
Escalator Step<br />
Cast Wheel<br />
Appllication<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Escalator<br />
Aluminum high-pressure die-casting<br />
AlSi12<br />
8.5 kg<br />
Casting, punching,<br />
machining, coating<br />
Application<br />
Dozer drive wheel<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-7<br />
Weight<br />
154 kg<br />
Value Chain<br />
Casting, machining<br />
Your Advantage<br />
• Weight reduction<br />
Your Advantage<br />
• Coreless bionic design<br />
80 Innovative Products for you Innovative Products for you 81
Portal Axle Housing<br />
Application<br />
Agricultural machinery<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-14<br />
Weight<br />
343 kg<br />
Value Chain<br />
Casting<br />
Driver<br />
Application<br />
Dozer chassis<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-14<br />
Weight<br />
300 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Produced with 3D-printed sand cores<br />
Your Advantage<br />
• Complex core structure<br />
• Produced with 3D-printed sand cores<br />
82 Innovative Products for you Innovative Products for you 83
Axle Housing<br />
Application<br />
Construction equipment<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-14<br />
Weight<br />
792 kg<br />
Value Chain<br />
Casting<br />
Bearing Housing<br />
Application<br />
Turbocharger<br />
Process<br />
Iron sandcasting<br />
Material GJS 500-14<br />
Weight<br />
389 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Component length over 2.4 m<br />
Your Advantage<br />
• Extreme reduction of machining and optimization of the flow<br />
behavior thanks to integrated tubes<br />
84 Innovative Products for you Innovative Products for you 85
Rear Axle Housing<br />
Process<br />
Iron sandcasting<br />
Material GJL 250<br />
Weight<br />
588 kg<br />
Value Chain<br />
Casting<br />
Housing Cover<br />
Application<br />
Wind turbine<br />
Process<br />
Iron sandcasting<br />
Material GJS 400-18<br />
Weight<br />
920 kg<br />
Value Chain<br />
Casting<br />
Your Advantage<br />
• Very compley component<br />
Your Advantage<br />
• Functional integration<br />
86 Innovative Products for you Innovative Products for you 87
Lighting Body and Cover<br />
Lighting Housing<br />
Application<br />
Process<br />
Material<br />
Body Weight<br />
Cover Weight<br />
Value Chain<br />
Outdoor Lighting<br />
Aluminum high-pressure die-casting<br />
AlSi12Cu1(Fe)<br />
3.2 kg<br />
2.9 kg<br />
Casting, trimming, manual finishing<br />
Application<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Indoor Lighting<br />
Aluminum high-pressure die-casting<br />
AlMg9Cu3(Fe)<br />
3.1 kg<br />
Casting, trimming, manual finishing,<br />
shot-blasting<br />
Your Advantage<br />
Your Advantage<br />
• Development together with the customer<br />
• New generation LED lighting<br />
• Weight reduction study in co-development phase<br />
• Highly aesthetic component<br />
• Cost efficiency through two casting-tool concepts with<br />
cavities<br />
• Reduction of machining effort through complex casting<br />
• Development together with the customer to improve filling<br />
and casting features<br />
• Highly aesthetic component<br />
88 Innovative Products for you Innovative Products for you 89
Decorative Angle<br />
Application<br />
Process<br />
Material<br />
Weight<br />
Value Chain<br />
Refrigerator<br />
Aluminum high-pressure die-casting<br />
AlSi9Cu3(Fe)<br />
0.5 kg<br />
Casting, trimming, shot-blasting, machinig, robot<br />
grinding, manual finishing, painting<br />
Organisation<br />
One of three international Divisions belonging to the Georg Fischer Corporation listed at the Swiss stock exchange<br />
Main Activity<br />
Development, production and machining of high performance cast components in Aluminum, Magnesium and iron for the<br />
automotive industry, their suppliers and a variety of industrial applications as well as investment casting for the aerospace and<br />
industrial gas turbines industry.<br />
Your Advantage<br />
Production sites<br />
Switzerland, Germany, Austria, Romania, China and the USA<br />
• Reduction of machining effort<br />
• Optimized processes and materials<br />
Employees<br />
• No additional machining<br />
6500 worldwide<br />
• Highly aesthetic component<br />
Special Features<br />
• World class development and serial production partner for automotive, commercial vehicle and industrial applications<br />
• Complex lightweight components in iron sandcasting, Aluminum and Magnesium high-pressure die-casting, investment casting and<br />
additive manufacturing<br />
• 17 production sites and 2 R&D centers<br />
• Development, casting, heat-treatment, coating and assembly<br />
90 Innovative Products for you<br />
• Optimal combination of bionic design, innovative materials and efficient manufacturing processes for lightweight solutions to reduce<br />
CO<br />
Innovative Products for you 91<br />
2 emissions
www.gfcs.com<br />
92 Innovative Products for you
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