“GJSlim” research project for ultralight cast structures


“GJSlim” research project for ultralight cast structures

Copyright: © Unsplash / Francisco Fernandes

The GJSlim project combines knowledge from foundry technology, lightweight construction and operational stability. Structures made of cast iron with spheroidal graphite with wall thicknesses of less than 5mm should be cyclically resilient. The Foundry Institute (GI), which is part of the Division of Materials Science and Engineering, is also partcipating in the project.

The aim of the project is to develop a transferable lightweight construction concept for ultra-light and cyclically highly resilient structures made of spheroidal graphite cast iron (GJS) with wall thicknesses of less than 5mm. To this end, the consortium partners, led by RWTH Aachen University, want to demonstrate fundamental dependencies between design and process optimization as well as local component properties. With the help of a digital twin, particularly thin GJS structures with the highest material and structural utilization should be possible.

Cast structures are already often used in functionally integrated lightweight construction. GJS in particular has a good property profile in terms of adjustable strength, ductility and stiffness. However, components made of this material often have locally different material properties, for example due to different component wall thicknesses, which are only taken into account to a limited extent in the component design.

A total of ten partners are taking part in the project, which is funded by the Federal Ministry for Economic Affairs and Climate Protection (BMWK):

  • Foundry Institute (GI) of RWTH Aachen
  • Institute for Structural Mechanics and Lightweight Construction (SLA) at RWTH Aachen
  • Fraunhofer LBF
  • MAGMA Foundry Technology GmbH
  • Intes GmbH
  • Franken Guss GmbH & Co. KG
  • Hüttenes-Albertus Chemical Works GmbH
  • Isselguss GmbH foundry products
  • FONDIUM B.V. & Co. KG
  • ASK Chemicals

Sources: Springer Professional and SLA from RWTH Aachen