Aluminium Die Casting

Rheocasting Expert on Demand

The article numbers in HPDC are expected to drop by up to 75%. This process will, in particular, hit the smaller DCMs that produce powertrain parts, which will become obsolete due to vehicle electrification or part integrations. So, it is time to look left and right for new parts to cast and fill the production line.
Great opportunities arise when you look at sand castings or die castings that run in large numbers. There are hundreds of such parts in the suspension systems of various cars. It gets especially interesting when you also consider truck beams and brackets. OEMs have to reduce the weight of the trucks to increase fuel or power efficiency.

Free Consultation

Do you need help unlocking the full potential of Rheocasting, High-Pressure Die-Casting, and Sustainability?

Casting-Campus GmbH helps you from the idea through the implementation into the production process. Book today a free consultation today to talk about your company’s potential.

Take over Die and Sand Castings into Rheocasting

There are several things to consider. The obvious one is that 90% of them are made of AlSi7Mg (A356), an alloy that is not usable in HPDC due to its soldering tendencies. The second aspect is that they have high wall thicknesses due to the necessary properties.

In the casting process, thick-walled die castings cool more slowly due to their lower surface area-to-volume ratio. The latent heat cannot be transferred out of the casting. Undercooling is less pronounced, resulting in fewer nucleation sites and coarser microstructures. Dendritic growth is more prominent in thick-walled castings, leading to larger dendrites and drastically reduced mechanical properties, particularly in terms of ductility. In addition, an energy-intensive two-step T6 heat treatment is always needed for die castings.
The shrinkage during the solidification phase change in aluminium is 6.6%, which causes porosity. This increases the problem for the thick-walled castings as more alloy is needed to compensate for the shrinkage, and the dendrite structure prohibits adequate feeding.
Rheocasting is the solution. The globular microstructure installed during the slurry-making process prohibits dendrites from forming. With its thixotropic properties, it can laminar fill thin- and thick-walled castings of outstanding quality. The pocket warmer effect allows for an extended feeding time to ensure the highest properties. Combine these benefits of Rheocasting with the high efficiency of a standard HPDC machine, and you get an unfair advantage for your foundry.

Our Approach: Tailored Strategies for Lasting Impact

At Casting-Campus GmbH, we understand that each foundry is unique, with its own set of challenges, goals, and resources. That's why we don't believe in one-size-fits-all solutions. Taking over Die Castings is just one of many applications that do not compete with other foundries. By reducing the weight and using T5 heat treatments, the sustainability is massively improved. There are way more exciting and profitable applications waiting for your foundry.

Our expert works closely with you to assess your specific targets and develop a customized Rheocasting strategy tailored to your foundry’s requirements. Each foundry has a different utilization depending on the machine size and preferred customers for their solutions.

Our Services:

Comprehensive Assessment

We start by thoroughly evaluating your current operations, capabilities, and market positioning. This assessment forms the foundation of our strategic recommendations.

Strategic Planning

Based on our assessment, we collaborate with your team to develop a detailed roadmap for integrating Rheocasting into your operations. From technology adoption to process optimization, we provide clear and actionable steps to maximize your success.

Content Creation

Developing a new market for your foundry requires strategically targeting the right people. A content-based social media strategy unlocks potential that goes beyond new customers. Think about attracting the best talents in the industry.

Technical Support:

Implementing Rheocasting requires more than just a strategic plan—it demands technical expertise. Our team offers hands-on support throughout the implementation process, ensuring a smooth transition and minimising disruptions to your production.

Training and Education:

Empowering your team is essential for long-term success. We provide comprehensive training programs tailored to your staff's needs, equipping them with the knowledge and skills required to excel in the Rheocasting environment.

Continuous Improvement:

The journey continues once Rheocasting is integrated into your foundry. We believe in ongoing support and collaboration to drive continuous improvement and optimise your operations for maximum efficiency and profitability.

Working with Casting-Campus GmbH is a different Experience

One of the biggest hurdles to hiring a consultant is the unpredictability of costs. As a consultant, you earn more money the more time you need to complete your tasks. As the hiring company, you want results that are as quick as possible. So, there is a misalignment of interests, which causes a lot of friction.

That doesn’t happen with Casting-Campus GmbH as your consultant. We removed the friction and misalignment of interests. When you hire us, you pay a flat monthly fee for our remote Rheocasting Strategy Development. It is like the Netflix of Knowledge.

We share your interests. We want to quickly provide you with the best solutions while maintaining the highest quality levels. In addition, you can predict your project costs exactly. It is a perfect match!

You can cancel the service anytime if we don’t deliver the expected quality, but we will deliver outstanding comprehensive services because we want to have a long-lasting partnership that accelerates your success.

As a remote consulting service, there is occasionally a need for on-site visits. The monthly fee does not cover these visits for customer meetings, exhibitions, and workshops. But, even as a Netflix subscriber, you must pay for their studio tour. It is the same for this business model. We have to charge for that if you want us on-site. But as a partner, you get a discounted rate.