ABOUT POWERTRAINS

PROCESS COMPARISON

	Aluminum	Lost Core	Welded	Adhesive
Design Flexibility	Best	Best	Good	Better
Tooling Costs	Best	Good	Better	Best
Process Complexity	Good	Good	Better	Best
Piece Price Cost	Medium	High	Low	Medium
Burst Test Levels	Best	Good	Better	Better
Technology	Best	Medium	Medium	Medium
NVH	Best	Best	Best	Best

• Providing the highest quality castings
• Leading capabilities in aluminum sand casting and composite/polymer molding
• Strong relationships with major global manufacturers
• Strategically located in North America
• Proven track record of tight tolerances
• Lean manufacturing culture

ALUMINUM INTAKES

Hayes Lemmerz has the ability to design, test, cast, machine and assemble. Our full-service capability is unique in the industry. Also, because we manufacture all of our powertrain products (cast and machined) in a single location, we generate logistics cost savings for our customers. Design features such as coatings, cast graphics, and high strength mounting bosses for accessories and wiring add to the cosmetics and functionality of the aluminum intake.

Cast aluminum intake manifolds are highly engineered products offering the ability for intricate coring, resulting in maximum flow characteristics and better NVH characteristics. Produced using green sand or semi-permanent mold processes, cast aluminum intakes are economically advantageous at all production volumes.

• Variety of processes - green sand or semi-permanent mold
• Intricate coring
• Improved NVH versus polymer
• Machining and assembly capability

COMPLEX CORED CASTINGS

Cast aluminum components are highly-engineered products offering the ability for intricate coring, resulting in maximum flow characteristics. Produced using green sand, cast aluminum components are economically advantageous at all production volumes. Hayes Lemmerz has the ability to design, test, cast, machine and assemble. Our full-service capability is unique in the industry. Also, because we manufacture all of our powertrain products (cast and machined) at a single location, we generate logistics cost savings for our customers.

• Water Pump Housings
• Intake Manifolds
• Integrated Air/Fuel Modules
• Inlet Ducts
• Water Bypass/Crossover

POLYMER PRODUCTS

Polymer intake manifolds are highly engineered products offering optimum performance for engines. Smooth interior runners allow for maximizing flow characteristics. Produced using the lost core or multi-piece welded process, polymer intakes are economical, thereby advantageous in high volume production. Full service capabilities include design, test, mold, and assembly, supplying the customer with a complete finished component. Design features such as cast graphics, tuned runner systems, and high strength mounting bosses for accessories and wiring add to the cosmetics and functionality of the intake.

• Accommodates large complex designs
• Variety of materials - Nylon 6, Nylon 6,6.
• Optimal air flow
• Weight reduction
• Volume production
• Improved engine hot start performance
• Molded in graphics

NEW PRODUCTS

Hybrid valve covers offer the following advantages, as compared to thermoset/aluminium:

• Lower cost
  • Reduced fasteners by 30% with Hybrid and up to 90% with Snap Clip
  • Reduced cylinder head processing (less drilling and tapping)
  • Less material for mounting bosses
  • Oil fill cap assembly is welded, not glued
• Lighter weight versus aluminium
• Aesthetics - injection molding process allows for flexibility to design in additional features such as logos, ribs and other marketing enhancements
• Environmental - thermoplastics are recyclable while thermoset is not.

Hayes Lemmerz is committed to bringing new products to the market place to keep up with the demanding requirements of our customers. Our full assembly capability results in cost savings for our customers by being able to reduce the number of suppliers they work with and having fewer part numbers and assembly requirements at their manufacturing plants.

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