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| Precision castings - integrity and accuracy |
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Using its patented Cosworth process (COSCAST™), which was originally developed to meet the exacting demands of racing engines, MAHLE Powertrain's foundry delivers high strength, lightweight aluminum castings for prototyping or series manufacture, with outstanding dimensional accuracy, integrity and freedom from residual stress.
The process uses zircon sand for the mold which, when compared to conventional silica sand, provides greater accuracy and stability, leading to improved cast-in feature content and opportunities for reduced machining requirements. This allows design freedom to optimize weight and enhance features. MAGMASOFT® simulation software, specifically tailored to the Cosworth process, enables early prediction of potential integrity issues and design for manufacture at the concept stage.
A key part of the process is metal preparation, ensuring cleanliness and maintaining integrity. Using its own electromagnetic pump metal delivery system, molds are filled in a non-turbulent manner, minimizing defect formation and maximizing both casting quality and durability. The use of gentle thermal sand removal significantly reduces the risk of distortion, thus enhancing dimensional accuracy.
The resulting aluminum casting can be lighter than an equivalent part produced by other proprietary processes, leading to improved performance with reduced fuel consumption and emissions.
Our in-house facilities include a metallurgical laboratory, real time x-ray monitoring, both static and portable co-ordinate measuring machines and electromagnetic pump metal delivery system manufacture. All are supported by a technical team with a significant number of years' experience with this unique process.