General information

Course name	Lecture: 04-326-MW-024 Light Metal Casting in Automotive Industry
Subtitle
Course number	04-326-MW-024
Semester	WiSe 2025/2026
Current number of participants	21
Home institute	M.Sc. Produktionstechnik-Maschinenbau & Verfahrenstechnik
Courses type	Lecture in category Teaching
First date	Monday, 13.10.2025 16:15 - 17:45
Type/Form
Participants	Studierende aus Produktionstechnik, Wirtschaftsingenieurwesen, etc. - alle Vertiefungen.
Pre-requisites	Die Veranstaltung ist grundlegend, stellt das Fertigungsverfahren Gießen mit Schwerpunkt auf Leichtmetallen und den für die Automobilindustrie besonders relevanten Werkstoffen und Verfahren vor. Grundlagen im Bereich der Werkstoffkunde metallischer Werkstoffe sind hilfreich, aber nicht unbedingt erforderlich.
Learning organisation	Vorlesung, ggf. Übung (MAGMASOFT Gießsimulationssoftware)
Performance record	schriftliche Ausarbeitung und Kurzvortrag vor den Teilnehmenden
Nachhaltigkeitsziel	Yes
Englischsprachige Veranstaltung	Ja
Miscellanea	Bei Teilnahme nicht deutschsprachiger Studierender wird die Veranstaltung in englischer Sprache angeboten.
ECTS points	3

Lecturers

Dr. Dirk Lehmhus

Rooms and times

No room preference: Monday: 16:15 - 17:45, weekly

Module assignments

Comment/Description

Casting involves producing a component that is close to its final shape from a molten state. The process itself has been known for millennia, but it remains highly significant in the automotive industry today and is currently the subject of dynamic developments.
Depending on the production volume and the components’ intended use, a wide variety of casting processes—ranging from sand and permanent mold casting to low-pressure and die casting—are employed, while aluminum alloys dominatethe materials used. At the same time, the foundry industry is currently facing massive challenges: OEMs’ shift toward electric mobility is changing the product range—castings that were previously indispensable in conventional powertrains, such as engine blocks, cylinder heads, oil pans, etc., are no longer in demand. This is leading to an increased focus on structural applications for castings as an alternative. This trend is further fueled by “Gigacasting,” a process first introduced by Tesla that involves combining a
large number of assembled components into a single, large cast part. This technology, in particular, requires further optimization of the monitoring and control of casting processes. This also increases the pressure on the foundry industry to address topics such as Industry 4.0 and data-driven process optimization—for example, using AI methods. This course provides an overview of foundry technology with a special focus on automotive applications, taking these current trends into account. The course is linked to
practical application through a tour of the Fraunhofer IFAM foundry technology center and, where possible, through a hands-on exercise in casting simulation using the MAGMASOFT® simulation software. The course requirement is a written paper on a specified or self-chosen topic related to the lecture material. A brief presentation to the group is also required.

Registration mode

After enrolment, participants will manually be selected.

Blockveranstaltung, Termin n.V.

Lecture: 04-326-MW-024 Light Metal Casting in Automotive Industry - Details