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High Pressure Die Casting (HPDC)
It is fully automatic casting process. Short cycle time provides high productivy. Therefore, process is ideal for high series.
In a last step of casting process, plunger press the melt into a casting die with a pressure 500-1000 bar.
With sophisticated HPDC machines become reality production of complex castings with low porosity and high mechanical propertis.
Talum cooperate with a HPDC process leader, company Bühler.
-Bühler Carat 105 (1050 t clamping force) -Bühler Carat 140 (1400 t clamping force)
Low pressure die casting
If we are to achieve best mechanical properties of highly mechanically loaded parts (safety components, assemblies ...) of aluminium castings, we use low pressure die casting. This procedure requires extended cycle times using a demanding technology, which results in higher prices of castings.
Casting on a low pressure die casting machine follows the principle of displacement of the melt from an airtight and electrically heated furnace into the permanent mould through a feeding system. The process is enabled by the pressure, supplied to the melt surface, whereas casting is performed bottom-up. For displacement of the melt from the furnace we use the air with a maximum pressure of 1 bar.
The solidification process of castings takes place in zones and is directed by locally supplied air currents on the outer side of the mould. At the end of the solidification process the pressure at the feeding core in the furnace is released and the melt falls back through the feeding pipe.
Gravity tilt casting
Gravity casting is basically divided in:
Classical gravity casting, where the casting machine rests and the aluminium melt flows into the mould due to its own gravity;
Gravity tilt casting, where the mould is clamped into the gravity tilt casting machine, which rotates for 90o causing the aluminium melt to flow into the mould in a controlled way.
Tilt casting machines:
Senator MBS, type KM8 (2 machines),
Senator MBS, type KM6 (6 machines),
Talum TSI, type KM6 (2 machines),
Senator MBS, type KM4 (2 machines).
Gravity casting machines can be operated manually or automatedly (with robots) depending on the size of the series.