Case study of lightweighting large aluminum castings using magnesium.

We will introduce a case where we successfully reduced reinforcement parts and replaced materials, achieving the intended weight reduction.

We received a request from a general parts manufacturer stating, "We would like to significantly reduce weight by changing all the large aluminum castings used in the vibration testing device's housing to magnesium." As a result, we achieved weight reduction using magnesium alloy. The customer commented, "The cost of the individual target parts has increased, but we successfully reduced reinforcement parts and replaced materials, achieving the desired weight reduction. We also appreciate that we could entrust the surface treatment against oxidation to a vendor, as there are not many handling magnesium casting." 【Method Details】 ■ Method: Precision sand casting ■ Material: AZ91D (magnesium alloy) ■ Heat treatment: None ■ Post-processing: Chemical treatment *For more details, please refer to the PDF document or feel free to contact us.

basic information

【Case Study】 <Challenges Before Implementation> ■ We want to reduce the weight of the equipment. ■ The vibrations affecting the equipment are strong, and in the case of aluminum, the number of reinforcement parts increases significantly. <Proposals> ■ Weight Reduction - Successfully reduced the total weight of parts from 600kg to 400kg. - Although the unit price of parts increased, significant cost reductions in auxiliary equipment such as drive motors allowed for a reduction in total costs. ■ Vibration Reduction - Magnesium has superior damping capabilities compared to aluminum, improving the vibrations of the casing. - This also contributed to the suppression of vibrations in surrounding components, leading to improved equipment performance. ■ Material Replacement with a Single Wooden Mold - Most compatible alloys can be cast using a single wooden mold. - Rapid material replacement is conducted according to customer requests, including simultaneous casting of multiple materials. *For more details, please refer to the PDF document or feel free to contact us.