As a result of constantly checking the effectiveness of our safety at work measures by means of internal and external audits, MAHLE has now achieved a maximum degree of safety. The consistent involvement of employees is a decisive factor in attaining this high standard. After all, the only way to reduce accidents and health hazards even further is to practice and apply safe behavior. Therefore, in a pilot project, we tested an interactive instruction module, which conveys important knowledge about safety at work to employees individually through self-training. The results of this project were extremely satisfactory for all participants; as a result, we will take the initial step of introducing this instruction module at all German-speaking MAHLE locations.

High standards in safety at work and environmental protection

Chlorine gas reduced by a further 20 percent worldwide
Because of the high oxidation potential and hydrogen solubility of aluminum melts, a melt cleansing process needs to be performed before casting. In order to achieve the required material quality in piston alloys, various “disruptive” elements such as calcium and sodium must also be removed. The use of chlorine is vital for this. In the conventional process used previously, chlorine gas was blown into the melt. Not only did this result in a high level of consumption, but the process was also dangerous for people and the environment. The search for alternative processes was imperative and led to some convincing solutions.

Today, all MAHLE foundry locations have melts that are cleansed using state-of-the-art technology in Foundry Degassing Units (FDU). In this process, the chlorine is steadily introduced into the melting bath via a rotor, the gases are extracted during the treatment and the solid foreign substances are transported to the surface of the bath. There they can finally be removed safely by the employees. In addition, the process avoids damage to buildings and equipment as a result of corrosion.

At one of our locations in the USA alone, this resulted in savings of 19 tons less chlorine per year in comparison with the average consumption using conventional technology – clearly easing the burden on the environment.