Being globally cost competitive in the thermal management product area has also allowed us to help customers consolidate their vendor base for custom metal fabrication.
Our quality control department has all the technology required that allow us to meet the highest expectations for the performance of our work.
You Can Expect Us To Deliver The Highest Quality Every-time.
Advanced Die Casting
Baknor offers our customers a choice for custom metal fabrication based on their requirements. This may be a technical requirement or may be a business case based on costs. This includes a wide spectrum of casting processes, materials and expertise to tailor an innovative solution for your products and parts.
Die casting is an ideal option in that it can provide complex metallic shapes within closer tolerances than any other mass production processes. Ongoing advancements in die casting technology have made it possible to cast in tight-tolerance features that once would have required multiple machining operations.
Die castings are processed at very high rates of production allowing for near net shape so little or no machining is required. This offers a manufacturability advantage that can reduce the piece-part costs of many metal components. Cost reduction from a machined requirement to a Die Cast part is very common.
Die Casting Advantages
Die casting can have significant advantages over other manufacturing processes, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. When you cast a part, you can create complex net shapes, including external threads and complex internal features with minimal draft angles—minimizing secondary operations. You can also combine multiple parts into a single part, eliminating assembly operations and lowering labor costs, with the added benefits of simplified stock control and greater component consistency.
-Tighter tolerances. -Variable wall thicknesses.
-Fast production cycle times. -Reduction in material scrap.
-Fewer steps from raw material to finished part. -Long tool life, especially for zinc &magnesium.
How are Die Castings Produced
First, a steel mold capable of producing tens of thousands of castings in rapid succession must be made in at least two sections to permit removal of castings. These sections are mounted securely in a machine and are arranged so that one is stationary (fixed die half) while the other is moveable (injector die half). To begin the casting cycle, the two die halves are clamped tightly together by the die casting machine. Molten metal is injected into the die cavity where it solidifies quickly. The die halves are drawn apart and the casting is ejected. Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting.
The complete cycle of the die casting process is by far the fastest known for producing precise non-ferrous metal parts. This is in marked contrast to sand casting which requires a new sand mold for each casting. While the permanent mold process uses iron or steel molds instead of sand, it is considerably slower, and not as precise as die casting.
Quality In Die Casting
Quality in die casting is maintained through the use of process controls and feedback between the process control computer and the die casting machine.
Process controllers may utilize microprocessors to access transducers mounted on the die casting machine, to obtain velocity, position, hydraulic pressure and tie-bar strain data, etc. The microprocessor then adjusts the die casting machine operation through special valves, thus assuring consistent castings shot after shot. The process controller also collects machine performance data for statistical analysis in quality control.
Baknor Advanced Die Casting Semi Solid Metal Casting (Rheocasting)
Rheocasting is a low cost semi-solid melt preparation process used in a wide variety of industries, including automotive, telecom and more. The term 'semi-solid' means that the molten metal is placed in a state in which part of the melt is in a solid phase. In a mixture of solid and liquid, the phenomena of thixotropy occurs, which means that the faster we shear the melt, the less force we need. The process offers a high-quality slurry with a high level of solid fraction to enhance laminar flow which is a requirement for the casting of complex shapes.
The commercial breakthrough came in 2018 and the roll out of capacity in underway on a global scale. Fifty percent of the installed capacity is for the production of components that are not possible to cast using high pressure die casting, which is why the process offers new markets for our customers. The process is implemented on die casting machines ranging from 500 tons and up in locking force.
Influence on production cost
Basically the process has been developed in the following areas of interest:
Short change over from High pressure die casting to Rheocasting in the production cell.
Short cycle time, slurry preparation is faster than the cycle time in the casting machine.
Low cost investment, using standard components a based on standard software.
There are a number of casting methods in the semi solid casting family of processes. The difference between the various processes on the market are: