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22. March 2016

Foundry Star Alliance presents a significant outlook for the Die Casting Industry

Foundry Star Alliance presents a significant outlook for the Die Casting Industry


First International Forum on “Advanced Light Metal Applications in the Automotive Industry”


It was a formidable assembly, when Riccardo Ferrario (IDRA Group) opened the First International Forum on “Advanced light Metal Applications in the Automotive Industry” in a winery close to Brescia/Italy.
On behalf of the Foundry Star Alliance Companies, Ferrario was proud of the fact that 170 participants from more than 50 international top foundries made sure that the event was totally sold out.

The professional program began with the requirements of big OEMs like BMW, Daimler, FAW, FCA, JLR and Tesla, and lectures were carried out from important Tier#1, Alloy producers, Aluminium experts and from a range of foundry equipment suppliers and associations.

Foundry Star Alliance (FSA)


FSA is an independent group of leading supplier companies, who decided to cooperate and combine efforts with the aim of better support within the rapid growth of the global light alloy pressure die casting markets. FSA Companies: IDRA, CoStamp, Fondarex, I.E.C.I., Stotek and Wollin.

Simpler, Standardized and More Reliable

The FSA vision is based on the challenging business of Industry 4.0, Foundry 4.0 and this also means HPDC 4.0. Integration, interconnectivity, 3D diagnostic, hub system and traceability should be possible with strong cooperation, just simpler with common standards and more reliability.

Excellent Times for the Die Casting Industry


There is no doubt that the global die casting industry is doing quite well, and this is mainly due to the increased demand of casted parts of the automotive industry. For all car segments, the proportion of aluminium and magnesium is increasing, also trucks, buses and trains seem to have more light weight parts in the future. OEMs are investing in their plants looking for more supplier capacities, higher requirements and more flexibility to achieve new designs and future concept cars, which contain more aluminium and magnesium usage.

The Limit of CO2 Emissions in 2020 Forces the Industry to Act

The today´s limit of CO2 emission will drop from 123g/100km to 95g/100km in 2020 and to avoid strict penalties the OEMs will have to meet the severe targets.
The history of the proportion of light weight components during the last 45 years shows exactly the engineering reactions due to relevant factors. During the petrol crisis in the 70es the OEMs started to develop smaller and more efficient, aerodynamic cars. The light metal share was about 30 Kg in a medium car, mainly wheels, smaller engines and gear components.

The aluminium and magnesium usage increased during the 80es up to 60 Kg per car as a result of green economy duties, so cylinder heads were made of aluminium. Even more development and requirements in the 90es, when passenger´s safety and comfort was a must, like ABS, all-wheel drive or air condition, which means more weight compensated by light weight parts up to 90 Kg per car.

Today the average aluminium, magnesium weight is about 150 Kg per car in a medium class car, but the weight is still about 1 ton like in the ´80.

The forthcoming CO2 emission limit will motivate the OEMs to accomplish the legal requirements and there is a potential of more than 220 Kg par car in light weight constructions like not only wheels, engine parts and transmission, but also suspension components, body and white structural parts and also seat and door frames will be commodities in the next years.

Who competes with HPDC?

Frankly speaking, the OEMs are interested in the most efficient processes and the best results and trend setting technologies. HPDC is in an excellent position, but they have to follow for instance the engine evolution from diesel gasoline engines to hybrid and full electric vehicles, with different engines and different light weight parts. Probably less kilos, but thinner and more complicated parts.
Furthermore there is the big industry of plastic parts and carbon fiber elements and also other aluminium technologies beside HPDC they always should follow with advisable respect.

The Die Casting Industry is Ready to Prepare

The International Forum was an excellent step in the right direction to be prepared and was advantageous for the entire Die Casting Industry.

The exchange of ideas, requirements and future milestones, supports all participants from the production to the supply chain. This conference was able to screen this more or less abstract item of Foundry 4.0, and put into perspective what we have to seriously consider in order to push the Die Casting Industry forward for the next decade.

As Riccardo Ferrario summarized in his thanks to all participants, the forum will take place again in 2018 together with the Foundry Star Alliance Companies.

Business Profile:

Riccardo Ferrario, is the initial founder of the Foundry Star Alliance (FSA) and a metallurgical engineer graduate. He has worked for TEKSID, Meridian as Vice President Meridian Europe and Managing Director Meridian Italy and for the Euralcom Group. In 2009 he joined the IDRA Group as General Manager, with the proper know-how from various business perspectives within the industry.


 Foundry Star Alliance - Gallery

1. International Forum Advanced Light Material Applications in the Automotive Industry


RAFFMETALL / Mr. Parona / Mr. Zambelli
Aluminum alloys commitment between trends and sustainability
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DAIMLER / Mr. Pfitzer
Aluminum-Structural-Castings for Body-in-White Application at Mercedes-Benz worldwide
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MAGNA COSMA / Mr. Jaques
Meeting the Demands of the Global OEMs from a Tier 1 Perspective
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FCA TEKSID / Mr. Airaldi
Teksid Aluminum. FCA Strategy for new Eco-Engines
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MERIDIAN / Mr. Berkmortel
Magnesium Applications in the Automotive Industry And Developing Trends
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IDRA / Mr. Stokes
HPDCM and their role in the Foundry Industry 4.0
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JLR / Mr. Rowley
Automotive body construction – the next 10 years
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BMW / Mr. Stärk
Design and process development for a 2 Cavity Magnesium Cross Car beam 7 Series BMW
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ENDURANCE / Mr. Mus
The HPDC Market in India
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STOTEK / Mr. Würtz
Dosing High Aluminum Quality
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FAW / Mr. Hai-Feng
The application of Mg Casting in Cars FAW   
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COSTAMP / Mr. Tombini
Beyond The Die: Some case histories of process Development and troubleshooting
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FONDAREX / Mr. Emmenegger
Technical considerations on the application of Vacuum structural parts
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WOLLIN / Mr. Wollin
Minimum quantity lubricant application for Structural parts
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IECI / Mr. Loghi
Advanced global thermal control through analysis Of die thermal drift
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TESLA / Mr. Adamo
Accelerate the Worlds Transition to sustainable Transport
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If you are interested in more details, please ask for download www.idragroup.com or service(at)foundry-planet.com

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