Unlock the Rheocasting advantage to secure high-volume casting contracts. Discover how switching from sand or die casting to Rheocasting cuts costs, reduces porosity, and boosts foundry margins.

Discover how semi-solid aluminium slurries lower porosity, improve mechanical properties and ensure stable casting quality through thixotropic flow behavior.

Discover significant Rheocasting cost savings in foundries. Learn how to extend tool life, reduce machine sizes, and increase recycled alloy content by adopting Rheocasting. This innovative process minimizes long-term operational costs while meeting high-quality standards for OEMs and Tier 1s.

Discover how advances in process control, alloy flexibility, and tool design make rheocasting a top choice for sustainable series production. Learn why Rheocasting outperforms traditional methods in properties, thermal conductivity, and tool longevity.

Explore the key differences and similarities in Rheocasting vs. Thixocasting, two advanced aluminium forming techniques that offer superior quality, flexibility, and cost efficiency for precision parts.

Discover how adjusting the solid fraction in Rheocasting can transform your production of climate compressor housings to meet the EU F-Gas Ban requirements, enabling castings that hold up to 160 bars of pressure while reducing porosity and enhancing product quality.

A high solid fraction in Rheocasting can unlock new business opportunities, overcome the limitations of HPDC, and achieve high-quality, leak-tight castings with improved mechanical properties by optimizing slurry flow behaviour.

Optimize your foundry’s potential with a customized rheocasting strategy from Casting-Campus GmbH. We assess your unique challenges and market position, providing a tailored roadmap to integrate rheocasting technology, improve processes, and target new markets. Our flat-rate consulting ensures predictable costs and high-quality solutions, enabling your foundry to succeed faster and more efficiently.

Rheocasting overcomes the challenges of sand and die casting, generating profitable casting opportunities for your HPDC foundry. Rheocasting improves surface finish and dimensional accuracy and reduces production times compared to traditional methods. Learn how this process enhances efficiency, lowers costs, and supports sustainability in aluminium foundries. Explore how Rheocasting can boost your foundry’s profitability and performance.

Understand why standard HPDC ingates are unsuitable for Rheocasting and how they negatively impact casting quality. Learn the importance of a uniform Rheocasting ingate design to maintain slurry integrity and optimize casting properties. Explore how tailored ingate solutions can enhance your casting process and resolve design limitations.

Porosity issues in HPDC lead to failed castings. Discover why improper tool setup and gating can hinder performance and how specific requirements impact casting results in Rheocasting trial castings. Learn from real-world examples why the setting disallowed the Rheocasting trial casting to solve the porosity problems. Start to prevent these issues before the trial casting even began.

Welding HPDC aluminium parts poses challenges such as porosity, thermal conductivity, and distortion. This article explores these issues and highlights research by Oscar Samuelsson and Isak Tillberg from Chalmers University of Technology on welding HPDC components to sheet metal. Their findings show that Rheocasting enhances weldability, offering improved quality and strength.

Assess how different manufacturing methods for heat sinks, including skiving, milling, extrusion, and casting, affect thermal management. Discover how Rheocasting offers high thermal conductivity and design flexibility, using low-silicon alloys to optimize heat dissipation in electronic components.

Discover new opportunities for permanent mold castings as HPDC demand drops. Shifting smaller DCMs towards casting thicker-walled parts like suspension components, truck beams, and brackets using rheocasting prevents dendrite formation. It enhances mechanical properties, ensuring higher quality and profitability for foundries.

Optimize Rheocasting performance by understanding the crucial role of venting in preventing defects caused by trapped air. Learn why proper venting design is essential for achieving superior casting quality, avoiding costly adjustments, and enhancing overall results in Rheocasting and HPDC.

Discover tailored risk mitigation strategies for driving success in foundry innovation technology projects, like Rheocasting. Learn how to manage uncertainties, involve customers early, leverage contractor expertise, and prioritize prototype development for growth and competitiveness.

As the EU F-Gas ban comes into effect in 2026, compressor housings must adapt to new refrigerants like R-32 and CO2. This article explores how the shift impacts HPDC components and presents Rheocasting as a solution to maintain leak-tight integrity and meet environmental regulations. Discover how to navigate these changes effectively.

Understand how a “never-solidifying” Rheocasting alloy enhances long flow lengths and improves casting quality by retaining latent heat within the melt, ideal for complex parts and demanding requirements.

Explore the diverse world of semi-solid casting, from thixocasting to rheocasting, and learn about various methods, such as mechanical stirring, electromagnetic fields, and ultrasonic waves, that enhance casting quality. Discover how understanding these methods can optimize your casting process and expand production capabilities.

Understand why controlling the solid fraction and slurry preparation is crucial for successful Rheocasting. Discover how the right method can expand your product range beyond HPDC’s limitations, reaching new markets and boosting production efficiency.

Rheocasting provides a viable replacement for forgings in climate compressors by overcoming the limitations of traditional HPDC methods. The new F-gas regulations require high leak-tight performance.

As the limits of HPDC are reached, Rheocasting offers solutions for high-heat conductivity, leak-tight components, and complex castings. Rheocasting ensures efficiency and cost-effectiveness across various industries.

Learn about Rheocasting from someone who brought several HPDC and Rheocasting parts from the design stage into series production. The parts ranged over several industries and had a shot weight range of 1,2 to 43,7 kg. In summary, you get the theoretical background and the application knowledge in one session.

Discover how Rheocasting transforms aluminium HPDC casting by enabling new applications in automotive and telecommunications markets. With benefits like lower porosity, improved thermal conductivity, and reduced production costs, Rheocasting provides access to high-margin segments previously dominated by sand and gravity casting.

Dendrites form in aluminum alloys during solidification, reducing mechanical properties and increasing porosity. Rheocasting prevents dendritic growth by using a semi-solid slurry with a globular microstructure, minimizing undercooling, improving flow, and enhancing casting quality and performance.

Rheocasting uses a semi-solid slurry with thixotropic behavior, allowing for improved flow and castability. Learn how this process, similar to the way ketchup flows when shaken, enhances aluminum casting by reducing viscosity under stress and increasing efficiency in HPDC production.

Discover how Rheocasting enhances flow length in gigacastings by maintaining higher temperatures in the melt through internal solidification, allowing melt fronts to recombine effectively over long distances, improving overall casting quality and reducing defects compared to traditional HPDC methods.

Discover how Rheocasting enhances the quality of compressor casting by minimizing shrinkage and porosity issues. This advanced casting process ensures leak-tight fuel systems and battery castings, reducing production waste and improving profitability. Learn more about utilizing Rheocasting for high-end CO2 compressors with the new F-Gas Ban.

GISS, SEED, and SAG-method rely on temperature-controlled cooling, leading to variable parameters due to changes in melt chemistry. RheoMetal, however, uses an aluminium “ice cube” called EEM from the same melt, ensuring consistent slurry characteristics and stable production, essential for high-quality Rheocasting.

The shift toward electric vehicles has reduced demand for powertrain parts, impacting foundries. Rheocasting allows for high-wall thickness castings, perfect for truck industry needs. This allows for lower prices for customers and increased profit margins for foundries. AlSi7Mg is perfectly castable in Rheocasting, simplifying material validation.

Reducing operating costs is crucial for survival with rising energy costs and interest rates. Initial investment, depreciation, energy costs, and spare parts influence the operating costs of a diecasting machine. Smaller, fully depreciated machines are more cost-effective. Rheocasting reduces the machine size by up to 50% compared to HPDC by improving the filling process and projected area. This significantly reduces machine costs, energy consumption, and spare parts. Typically, Rheocasting requires a 30-40% smaller die-casting machine, cutting operating costs and reducing the carbon footprint.

Comptech AB won the METEF Innovation Award and NADCA Casting of the Year 2022 for the Rivian hinge pillar, made with AlSi7Mg alloy using Rheocasting. This method avoids the high die wear typical in HPDC and delivers outstanding mechanical properties with a high solid fraction of 35-45%, achieving 170 MPa yield strength, 250 MPa ultimate tensile strength, and 10% elongation. The hinge pillar design reduces projected area by 50%, allowing smaller machine use, saving energy, and lowering hourly rates. Using the secondary alloy eccomelt356.2, the carbon footprint is minimized to 1.1 kg CO2 per kg Al, significantly less than the global average.

Rheocasting slurries behave differently, offering advantages in high pressure die casting dies. Unlike traditional HPDC, where liquid metal quickly fills every corner, semi-solid slurry tends to flow straight, potentially ignoring perpendicular features initially and leading to porosity or defects if air gets trapped. The 2022 NADCA paper by Hartlieb, Jansson, Tawil, and Bergeron explains that the laminar flow of Rheocasting pushes air out of the cavity without entrapping it, filling even thin and tall ribs easily. For more insights, refer to their detailed study on Rheocasting for Rivian’s production.

A Rheocasting slurry is cooler than liquid melt but maintains its temperature longer, enabling slower, laminar filling. This reduces porosity and improves mechanical properties. The key? Latent heat. As solidification happens on solid particles, they release heat into the surrounding metal, promoting better flow and filling.The Comptech Rheometal process ensures a homogeneous and consistent slurry without temperature regulation. That’s why Rheocasting is cool

Key properties of an effective heat sink are high thermal conductivity, leak tightness, corrosion resistance, and good mechanical properties. Machined aluminium blocks are costly. HPDC typically caps thermal conductivity at 150-160 W/mK. Rheocasting offers a solution. By reducing silicon to 1.7%, Rheocasting achieves thermal conductivities over 190 W/mK with average values around 170-180 W/mK and excellent castability. It is ideal for high-performance heat sinks in large 5G antennas.

Last week, I supported GTK with a trial casting program. It’s exciting to see growing interest in Rheocasting. Unlike other temperature-controlled methods, the Comptech Rheometal process delivered a stable outcome. The Comptech process uses Enthalpy Exchange Mass (EEM) for precise, mass-controlled cooling, ensuring consistency even with composition changes. Check out the video to see the Rheometal process in action.

Latent heat is key in Rheocasting! Like pocket warmers, Rheocasting slurries release latent heat during solidification, keeping the melt hotter for longer. This is perfect for long flow lengths in gigacasting, ensuring higher quality by maintaining melt front temperature and feedability. Discover the magic of Rheocasting today!

Temperature controlled slurries in Rheocasting are not production-stable! Small changes (0.8 Kelvin) in temperature affect the slurry quality, making consistent casting hard. RheoMetal’s process isn’t slurry-temperature-dependent, ensuring stable production. Discover why accuracy matters!

A patent search revealed 87 Rheocasting technologies; only GISS, SEED, and RheoMetal remain. GISS & SEED’s cooling methods lead to inconsistent casting. RheoMetal ensures stable production with its EEM method, making it ideal for high-quality, consistent HPDC. Hence, Casting-Campus GmbH partners with Comptech AB.