Hengst wins 2010 International Aluminum Die Casting Competition

Automotive supplier Hengst took the first prize at the 2010 International Aluminum Die Casting Competition for the category "Multi-function part." Representatives of the company were on hand on Jan. 18 to receive the award, which is offered by several associations, as part of the 2010 EUROGUSS trade fair in Nuremberg.

With this award, the expert jury honored a special multi-function part, which was developed by Hengst for engines produced by truck manufacturer Deutz, and which is now installed in series for Volvo and Renault trucks.

The cast part, which Hengst designed especially for Deutz engines, combines a number of different functions related to the engine and fluid management: from the oil filter system and oil cooling to the coolant pump and fuel filter. The module contains channels at the functional levels of the plate oil cooler, delivery pump and engine flange.

At the same time there is still sufficient space for a generator, a belt tightener, engine electronics and the fuel filter with integrated heating unit. Eight valves, five distribution connections and two sensors guarantee that all fluids are delivered to the right point at the right time.

The cast part therefore combines multiple functions: it carries assemblies, holds connected components, transports media and conducts heat exchange. The client's objective specified a thin-walled, light construction, along with a small installation space.

Other specifications for the developers were pressure-tight housing with high corrosion resistance and resistance to temperature changes. In addition, ease of installation and servicing, for example, during oil filter changes, also formed essential components of the technical specifications.

For the purpose of combining the advantages of light construction with a high degree of precision and pressure tightness, Hengst engineers decided to produce the module from one aluminum piece, using the pressure die cast method.

The result -- an extremely near net shaped part with long lean cores, valve seats and sealing faces without mechanical machining, as well as more than 60 pre-cast boreholes, which are produced in only one work step. High-quality casting technology produces an excellent structure, which is able to permanently withstand the dynamic requirements of a truck engine, the company states.

The series production part is produced at the company's foundry in Nordwalde, Muensterland -- one of the most modern pressure die casting operations in the world, according to Hengst. The foundry, which was founded in 2000, has approximately 120 employees and is able to smelt up to 12,000 tons of aluminum per year, which is then processed on 10 pressure die casting machines in the closing pressure area at up to 2,200 tons.

Hengst was the winner in the multi-function part section, one of two categories of this internationally recognized competition. The jury awarded the prize in Nuremberg to Christian Boehnke, Hengst Production Manager; Dr. Andreas Dworog, Foundry Manager; Wilhelm Ardes (Design); and Josef Potthoff (Production Technology).

The prize is awarded by the Association of the Aluminum Recycling Industry (VAR) and the Organization of European Aluminum Refiners and Remelters (OEA). They are supported by the Association of German Die Casting Works and the expert committee for pressure die casting of the Federal Association of the German Die Casting Industry (BDG). The objective is to promote communication of the high quality standard of aluminum die casting processes to the general public.

For more information, visit www.hengst.com.