Light Alloy Foundries in


BIOS 1861


Reported by

T.H. Hall,    M.C.S. (Leader)

Dr. R. Potvin,    Canada

J.M. Berry,    M.O.S.

A. Eydon,    M.O.S.

A Graham,    M.O.S.

F. Howitt,    M.O.S.

Dr. O.R.J. Lee,    M.O.S.

A.J. Murphy,    M.O.S.

J.F. Paige, M.O.S.

K.S. Rawlins,    M.O.S.


B.I.O.S. Trip No. 951    August, 1945


C.I.O.S. Black List Item No. 21.



For practical reasons, this document have been copied partially. Some page being skipped due to an apparent electrostatic failure in a copier


We focus onto the two main German die casting companies Mahle and Aluminiumwerke Nürnberg G.m.b.H. (also known as: Nüral, AOB)


Keywords:    Mahle Stuttgart / Bad Canstatt

Mahle K.G. Stuttgart Fellbach    The factory of the Mahle group had specialised in pressure die castings and was the most important of its kind in Germany. The magnesium alloys, aluminium alloys and zinc alloys were cast and the range of products was very wide.

A relatively small shadow plant known as F. Eichert was located at Eislingen . It was equipped with ...



Ernst Mahle - Owner

Dr. A. Bauer - Chief Engineer Bauer's political activities had led to his exclusion from the work and the only person available for interrogation was Dr. Mayer

Gustav Lieby - Manager

Dr. Mayer - Deputy Manager

Workers employed 1939 - 1944 - 1945 ...

All the vertical hot-chamber machines designed by Mahle were built by Müller, Eislingen.

The factory was quite free from air-raid damage

Alloys used: Magnesium Alloys - Aluminium Alloys - Zinc Alloys

Die casting practice ... Vertical Hot-Chamber Machines ... All magnesium alloy castings were made on the hot chamber machines and it is worth noting that this is in direct contrast to the practice at V.D.M. Heddenheim where could-chamber machines of the Polak type were used ..

... The closing pressure of the die itself was about 80,000 Kg (80 tons)

The Polak Type Cold Chamber Machines were used primarily for aluminium or zinc and the Polak-type machines were considered to be the best cold chamber available ...

Production rates

Production costs ..  Melting costs ...

The cost of ingot metal was stated as follows:

Magnesium alloys    1450 R.M. per ton

Aluminium alloys    1400 R.M. per ton

Zinc alloys                 600 R.M. per ton

Melting practice

Metal Recovery

Tail wheel castings ...

Sample from a V2 rocket casting

Aluminiumwerke Nürnberg (Nural, Nüral)

This is one of the largest and best known light alloy foundry plants in germany. The 1939 production was 2,800 tons rising to 6,500 tons in 1944. The firm specialised in die casting and cast 40% of pistons in Germany allso taking the major part in die casting air cooled cylinder heads for aircraft engines (BMW 801)

Personnel Executives available at plant:

Wilhelm Däubel    Commercial-Manager

Hans Smohling (Schmöhling? AOB) Prokurist? AOB engineer - -chief

Rudolf Schitt    Prokurist?  Diplom-ing.

Willi Merz    Prokurist?

Dr. Max Kuhm (Kuhn, Kühn? AOB)

Alloys used: Lo-Ex - "Y" Alloy and 10% Cu - Hydroalium - Silumin beta and gamma - Secondary alloy - Zinc alloy -

Elektron A.8 Magnesium alloy containing 8% Al for pressure die castings mainly radio chassis. This alloy was used for thin walled parts (2 mm thick) because of its fluidity


Silumin Practice The alloy ingot was supplied by Silumin Gesellschaft, Frankfurt and by Lautewerke Saxony.

Degassing ...

Hydronalium Practice ...

Magnesium Foundry Melting Practice  Production was 5-10 tons per month of pressure die-castings in the alloy "A.8". The metal was melted in Schmitz and Appelt gas-fired furnaces of 200 kgs capacity in two to three hours. ...

Heat Treatement

Moulding Sand ...

Pressure Die Casting ..... Gmöhling machines was made by Werner and Pfeiderer of Stuttgart (Bad-Cannstatt)

Re-Melt Department

pistons were all coated with lead ...

The Perner Process for lead coating aluminium pistons ...




Please go back to, or proceed with: FIAT-CIOS-BIOS page