Boost Your Margins and Minimise Tool Wear with Rheocasting

As the market dynamics shift, foundries are under increasing pressure to find innovative ways to stay competitive, cut costs, minimise tool wear, and improve the quality of their products. One effective solution that can significantly benefit your operations is Rheocasting, especially when working with HPDC components made from the versatile A380 aluminium alloy.

Why focus on the A380 alloy?

A380 is one of the most widely used aluminium alloys in the die-casting industry. It is known for its excellent machinability and strength. It’s extensively used for components in both automotive and non-automotive applications, from gearbox housings and engine blocks to structural parts and electronic enclosures.

The usual process for implementing Rheocasting is changing the alloy to a low-silicon alloy. However, the specification allows reducing the silicon content to 7.5% for the A380 and 8.0% for the 226. Because of the high copper content in these alloys, the solidification interval is large enough to operate Rheocasting safely in your production.

As all specifications stay the same, implementing Rheocasting is as easy as buying a new peripheral for your HPDC cell. Include it in your production, qualify it, and start production.

Here’s how Rheocasting transforms your A380 HPDC Projects:

Optimise Your Margins by Reducing Defects

Rheocasting is a semi-solid casting process that enables a more controlled, less turbulent flow of the alloy into the mould, reducing the risk of defects such as porosity and shrinkage. For A380 castings, this means fewer quality issues and rejections, directly translating into cost savings. Imagine reducing your scrap rates from 5% to 0.5%—those savings quickly add up, especially when producing high volumes.

Stay within Specifications without Alloy Changes

One of the biggest hurdles when adopting new casting techniques is the need to change alloy compositions, which can disrupt production and increase costs. With rheocasting, you don’t need to change from A380 alloy. By adjusting the rheocasting process parameters, you can work within the existing A380 specifications, maintaining compliance while achieving a higher-quality casting. This simplifies implementation and keeps your production lines running smoothly.

Extend Tool Life and Minimise Wear

Tool wear is a costly challenge in high-pressure die-casting, especially when working with A380, which can be abrasive due to its high silicon and copper content. Rheocasting can extend the life of your tools by reducing the temperatures and metal speeds involved in the casting process. The semi-solid slurry used in Rheocasting is less abrasive and generates lower mechanical stress, meaning your dies last longer and require less frequent maintenance. This reduces downtime and replacement costs, further boosting your profitability. It also reduces the cost of all these people manually deburring the heat cracks of your tools.

Tackle Challenging Parts with Confidence

A380 is often used in parts with complex geometries, high wall thickness variations, and strict tolerance requirements, such as transmission housings, engine covers, and electronic casings. Many pump and valve housings also have leakage requirements. Rheocasting is particularly suited for these challenging parts, as it guarantees good filling and feeding, resulting in extremely low porosity and rejection rates.

Take Action Now to Stay Ahead:

Implementing Rheocasting for your A380/226 alloy castings can reduce costs, extend tool life, and improve overall competitiveness. With this innovative approach, your foundry can optimise margins, maintain high-quality standards, and reduce the headaches associated with high tool wear and defect rates.

Don’t let your foundry get left behind. Embrace Rheocasting to make the most of the proven benefits of A380/226 aluminium alloy and gain a competitive edge in a fast-evolving industry. For more information, visit the Rheocasting Workshop and listen to the upcoming podcast episode Gold Nugget 29.