E-Axle Housing

Development & Production

To bring this e-mobility solution from initial design into serial production, GF supported the castability optimization process. To contribute to a castable and reliable solution, GF offers the analysis of the castability, ingate design, various simulations and evaluation of potential risk areas. Once the solution is ready for serial production, key experts are managing the production process as well as quality verification.

Challenges & Special Features

This e-axle housing, which is part of the electric drive unit, needs to fulfill very high leakage proof standards. During the die casting process, extremely high temperatures and pressures are shaping the thin-walled component and many parameters need to be 100 % accurate. To optimize the component for a leakage rate less than 0.5 %, several optimization loops are usually needed before the reliable and high-quality serial production can start. Key is to reach the right balance of all parameters.

Features

Customer Volkswagen
Vehicle MEB
Process Aluminum high-pressure die-casting
Material AlSi10Mg(Fe) 
Weight 8.5 kg
Value Chain Casting, trimming, machining

Highlights

  • Agile design optimization process in close collaboration with customer
  • Verified leak-proof solution (leakage rate below 0.5 %)