The new process

Magnesium and Aluminium Gas Injection Technology

MAGIT is the new gas injection technology for creating completely new die casting applications such as power electronic housings with integrated cooling lines and other hollow magnesium and aluminium die-cast structures.

This technology involves the still liquid melt at the core of the component being displaced into an opening overflow cavity during the cooling phase.

MAGIT PROCESS ANIMATION

Our

Services

Our philosophy encompasses a holistic support and consultation service from component development and die design and construction to the actual die casting process.

Our experienced engineers assist you in using our new MAGIT gas injection process and the associated plant technology successfully in high-pressure die casting – from the outset, through each development stage of your component, planning and commissioning to process optimising.



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Plant technology

The new MAGIT plant technology consists of all components which, together, are responsible for successful implementation of a reproducible process:

  • Stand-alone system for connection to existing die casting cells
  • Effective compressor unit:
    Efficient gas compression to over 500 bar
  • Integrated hydraulic supply:
    Supplies die modules with up to 250 bar
  • Integrated accumulator modules:
    Providing two pressure levels for melt displacement
    and holding pressure
  • Real-time control:
    For reproducible gas injection within 5 ms
  • Number of cavities:
    Single or dual cavity plants are available

MAGIT 2-cavity power module

Diagram of MAGIT plant technology


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Component development

Gas-compatible component design

  • Functional integration (avoidance of friction stir welding or inserts)
  • Optimum duct dimensioning and course
  • Integration of gas brakes
  • Design of duct connection geometries (screw bosses, ribbing)

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Simulation

Solidification and filling simulation

  • Casting layout with MAGMA software
  • Simulation of solidification phase, taking gas injection into consideration
  • Theoretical determination of duct wall thickness
  • Determination of cavity volume

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Die concept

Creation of die concepts

  • Specification of ideal injector positions and overflows
  • Definition of component position in die
  • Dimensioning and positioning of gate valve
  • Layout of overflow cavity

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Injector technology

MAGIT injector

The injector technology, which enables the reproducible introduction of gas to the interior of the die-cast component, is decisive for the success of this gas injection technology.

The injection process for the gas and, consequently, the quality of industrial-scale die-cast components can only be assured with the injectors appropriate for use with MAGIT.

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Die modules

Die-adapted injection and overflow cavity modules

consisting of the following:

  • Connection plates with standardised hydraulic, cooling water, gas supply and sensor connections
  • Different injector and gate valve lengths adapted to suit die
  • Tool inserts for overflow and injection duct

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Process optimizing

Process optimising of MAGIT process following commissioning and installation of new dies

  • Optimising of gas injection
  • Optimising of injector and gate valve opening and closing times
  • Adaptation of overflow volume
  • Optimising of clearing and holding pressure

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Component testing

Broad range of diverse component tests

  • Testing pursuant to LV 124
  • Vibration testing (on 24 KN and 70 kN shakers)
  • Static and dynamic burst pressure testing
  • Flow testing (oil, glycol, water)
  • Climatic chambers
  • Leak tests
  • Pressure loss measurements (air, oil, glycol, water)
  • Pulsation tests (air, hot air, oil, glycol, water)

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Service & training

We offer complete post-commissioning support with the following:

  • Operator training
  • Prompt replacement and wear part supply
  • 
Support during maintenance and service work
  • Service training

Our

Partners

European Commission

H2020-EIC-FTI-2018-2020

This project has received funding from the European Union‘s Horizon 2020 research and innovation programme under grant agreement No 950866


We are currently working together with three partners in the context of the European Fast Track to Innovation (FTI) support and funding programme:

Prof. Dr.-Ing. Lothar H. Kallien
Aalen University
Beethovenstr. 1
D-73430 Aalen

www.hs-aalen.de

René Wagner
CEO / Inhaber
ALUWAG AG
Nellen 12
CH-9246 Niederbüren

www.aluwag.ch

Harry Vangansewinkel
Technical Sales Engineer
Surtechno nv
Siberiëstraat 5
B-3900 PELT

www.surtechno.be


We are member of the Innovation Network Gas Injection in Die Casting

Interesting facts for you

Downloads

“A breakthrough in production of light metal components” (2018-07 MAGIT published by Horizon 2020 de)

2018-07 MAGIT Vero#U0308ffentlichung durch Horizon 2020 en.pdf (231.5 KiB)

Download our MAGIT information flyer here

MAGIT Flyer fk_en.pdf (762.1 KiB)

Your

Contact

Franz Krall

Sales & Technology

Mobile: +49 173 8525112
Email: franz.krall@magit-hpdc.com

Lärchenwaldstrasse 18
4820 Bad Ischl
Austria

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