Lightweight Magnesium Cross Car Beam (CCB): GF Casting Solutions wins European Die Casting Award 2022

The GF cross car beam of the S-Class was awarded first prize in the Magnesium category of the European Die Casting Award 2022. With great joy and pride about the award, Stephan Philipp, Team Lead Product Development at GF Casting Solutions AG, accepted the prize on behalf of GF on January 18, 2022.

Excellent lightweight design

The die-cast magnesium cross car beam was awarded, among other things, for its design adapted to the very narrow environment. Even under dynamic loads, the CCB withstands the stresses due to its stiffness, in order to minimize vibrations around the steering wheel and the head-up display to the specified level. Simultaneously, in the event of a frontal crash, the component must allow a high degree of deformation (energy absorption) without fracture to ensure that it does not pose a danger to the passengers. Finally, the CCB's additional brackets, which were also developed at GF Casting Solutions, allow various add-on parts to be attached, which otherwise could only have been mounted in an extremely complex manner or not at all.

Within the framework of product development, casting simulations were continuously carried out in parallel with the CAD design, while the results of these simulations were fed back into further component design and tooling technology (Altenmarkt plant).

The prototypes were tested with the highest level of care with regard to their microstructure, surface condition and structural damage (cracks) and sent to the customer for further use.

The awarded component: a cross car beam (CCB) for Daimler AG’s current S-class

The structural part is made of the magnesium-aluminum alloy AM50 and weighs only 3.48 kg at dimensions of 1523 mm x 508 mm x 300 mm. Due to the possibility of complex component shaping, small wall thicknesses and small tolerances (near net shape), die casting offers optimum utilization of the very limited installation space, yet a design that is suitable for the stresses. The good yielding properties (smallest wall thicknesses) and low density of magnesium make it possible to produce very lightweight yet stiff designs. The component was developed jointly with Daimler AG and the GF plant in Altenmarkt (Austria) where it is also manufactured.

Among all casting solutions taking part in the competition, a highly qualified jury out of scientists and industry experts chose the best components with a special eye on innovation, quality, economic viability, resource-efficient construction and complexity.

New award for the European Die Casting Industry

For the first time, the German Die Casting Association (Verband Deutscher Druckgießereien e.V. - VDD) and the trade fair EUROGUSS organize the European Die Casting Competition. The competition is intended to show to the public and to customers the diversity of applications, the innovative strength, the high level of quality and the performance of the die-casting process in the materials aluminum, magnesium and zinc. The live recording of the event is published on the Euroguss YouTube channel.

Due to the current pandemic situation, the EUROGUSS 2022 was postponed to June 2022 and will take place at Nuremberg Messe from June 08-10, 2022. Visit GF Casting Solutions at booth 120 in hall 7A. The team is looking forward to meeting you there!