Design of the model device by CAD as per available 3D data.
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Manufacture of the individual model parts on the 5-axes milling machine.
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Complete pattern plate halves with casting and feeder technique.
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Moulded upper side as dead sand mould.
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Cores ready for installation to show cavities and undercuts for the use in the sand mould.
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Preparation of the sand mould for assembly.
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Assembly of the mould parts to a mould ready for casting.
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A mould prepared for casting.
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Identification of the alloy components by spectral analysis.
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Provision of the magnesium melt to cast the mould.
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The sand mould is "cast", i.e. filled with the magnesium melt.
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Demoulding of the casting after solidification of the melt.
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Casting and feeder technique is removed, the casting is fettled.
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First inspections at the finished blank.
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X-ray testing of the casting to check the internal condition of the component.
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Microscopic testing of the casting material structure.
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Mechanical treatment of the casting on a 5-axes machining centre.
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Dimensional testing after machining on a NC measuring machine.
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Casing ready for assembly
for a 20,000 watt head lamp made of magnesium casting with heat-resistant coating.
Diameter: approx. 700 mm
Height: approx. 350 mm
Weight: approx. 6.70 kg
Alloy: G-MgAl9Zn1 (magnesium AZ 91hp)
Wall thickness: min. 3mm
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