In the frame of the public funded project InDrutec-E both aluminium- and magnesium-based lightweight concepts were developed, investigated and demonstrated using the example of a gearbox cover in the electric drive train. The project was funded by the Federal Ministry of Economics and Climate Action. The project partners DLR Institut für Fahrzeugkonzepte, Robert Bosch GmbH, Oskar Frech GmbH + Co. KG, Gühring KG and the Aalen University of Applied Science supported by the associated partners Andreas Stihl AG & Co. and EJOT SE & Co. KG worked successfully together over the past 3 years to achieve outstanding results. 

In comparison to a functionally identical aluminium reference component, the weight of the optimised aluminium lightweight design was reduced by 34 % and the weight of a respective magnesium lightweight design by 51%.

By using a high-strength aluminium cast alloy, Al-Mg-Si-Mn, with recycling content of 90%, the CO2eq of the aluminium lightweight design could be reduced by 86 % per casting part. The examined Al-MgSi-Mn aluminium alloy exhibited outstanding mechanical properties as well as excellent corrosion resistance.

Thanks to the lightweight construction effect and the application of green magnesium, the CO2eq of the magnesium based lightweight design was significantly reduced by 63 % per casting part. By further developing the Vacural® casting process of Oskar Frech GmbH for magnesium cold chamber casting, the quality of the magnesium casting has been improved. In addition to the benefits in weight and Co2eq a positive effect in cost is achieved at least by using less material.