Klassifizierung und Charakterisierung von verfahrensbedingten Gussfehlern in einem innovativen Kokillen-Giessverfahren

Translated title of the contribution: Analysis and classification of process-based casting defaults caused by an innovative gravity die casting process

Klaus-Peter Tucan

Research output: ThesisMaster's Thesis

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BMW developed the so called "injector casting" process in Landshut. It wass tested at a gravity mold casting plant. The procedure allows a new innovative production of cylinder heads. In the pre-development phase the procedure at two cylinder heads was tested. It concerns here the Four-cylinders cylinder head (internal designation N20) and a V8-Clyinders head (internal designation N63). During the production of the cylinder heads in the ICA procedure an increase of system based defects was mentioned. The defect analysis of the two kinds of cylinder where accomplished in destructive and none distructive examination. For non destructive examination leak test and computer tomography were used. Another non destructive method for statistic analysis, the so called "quasar testing method" for the detection of the failures has been analysed. Only a medium number of cylinder heads of the type N63 was checked up with this procedure. For the destructive examination it was necessary to brake up the parts several times to open and see the defects. The analyses were accomplished in cooperation with the laboratories of BMW Group. The following analysis comprised scanning electron microscopy with EDX Analysis, stereo and light microscopy and computer tomography with microfocus. A comparative overview of the kinds of defects and their possible emergence causes, conclusions on process parameters and statistic evaluations were provided. In accompanying simulation mould filling, temperature-ranges and oxidation inclination during the casting procedure were examined.
Translated title of the contributionAnalysis and classification of process-based casting defaults caused by an innovative gravity die casting process
Original languageGerman
  • Schumacher, Peter, Supervisor (internal)
  • Hanss, Timo, Supervisor (external), External person
Award date4 Apr 2014
Publication statusPublished - 2014

Bibliographical note

embargoed until null


  • oxite
  • defect
  • cylinder
  • head
  • gravity casting
  • analysis

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