Mega-casting in the automotive production system: Expert interview-based impact analysis of large-format aluminium high-pressure die-casting (HPDC) on the vehicle production

Journal of Manufacturing Processes, vol. 124, pp. 918–935

Abstract

Since the revolutionary invention of the conveyor-belt production by Henry Ford in 1913, market player mainly evolved a unique selling point through E-Mobility. Mega-Casting promises a revolutionary simplification of the automotive production system using large-format high-pressure die-cast (HPDC) aluminium structural components in the automotive car body. Through 35 cross-industry expert interviews in the automotive production system, the paper's study has the aim to (1) present first time the analysis of the disrupting Mega-Casting automotive production concept. Based on grounded theory and coding methodology, the economical, ecological, sociological, strategical, and technical potential of Mega-Casting has been assessed to identify its differences and thus the impact on the automotive production system. (2) Expert view on opportunities and challenges of Mega-Casting for each TIER-level in the production system through a detailed Mega-Casting production concept case study.

Authors 5

1. Peter Burggräf

   University of Siegen

   Affiliation as printed

   Chair of International Production Engineering and Management, University of Siegen, Siegen, Germany

2. Georg Bergweiler Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany

3. Stefan Kehrer Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany

4. Tobias Krawczyk Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany

5. Falko Fiedler corresponding Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany