Do Tier 1s and OEMs have to build new Supply Chains?

For most HPDC parts, there is no need to change anything. Yet, there is one where regulations force complete change. It is for compressor housings. For years, the refrigerant R134a has been used in everything from refrigerators to car climate systems. In 2026, the EU F-Gas ban will come into action. It serves as a linchpin in the global endeavour to mitigate climate change by phasing out high-global-warming-potential (GWP) fluorinated gases (F-gases).

Global Warming Potential (GWP) is a critical metric in evaluating the environmental impact of refrigerants. CO2, with a GWP of 1, emerges as a benchmark, reflecting its minimal contribution to global warming over a specified time period. In contrast, R-32, while an improvement over some traditional refrigerants, carries a higher GWP.

Among the alternatives gaining traction are R-32 and CO2, both offering distinct environmental benefits. It is a catastrophe for the Tier 1s and OEMs supply chain. To cast compressor housings, hundreds of HPDC machines worldwide produce them. They are leak-tight for the R134a gas.

Where is the issue when you change the gas within the air cooling unit?

R-32, while presenting a lower GWP than some traditional refrigerants, introduces a trade-off in the form of higher operating pressures. This is a consequence of its thermodynamic properties, including a higher pressure-temperature relationship. The shift to R-32 requires careful consideration of equipment compatibility and safety measures. Components and materials must be compatible with the increased operating pressures.

CO2, or R-744 in refrigerant terminology, garners attention for its environmental friendliness. Being a natural component of the Earth’s atmosphere, CO2 is abundant and non-toxic. Its use as a refrigerant aligns with sustainability goals, offering a solution that minimizes environmental impact.

In short, the smaller the molecule, the higher the pressure needed to operate in a two-phase (liquid and gas) phase area. With increased pressure and small molecules, the issue arises. Standard HPDC parts are leaking, and the cooling system loses its functionality. Even impregnation doesn’t help the HPDC parts, as the gas can penetrate them.

Low-pressure die casting and forging can deliver the required properties. Yet the capacity is unavailable, and no customer is willing to pay 5 to 10 times the price for the same part. At the same time, they are rendering the investment in these hundreds of DCMs worthless.

Is there a possibility of using these DCMs for the new applications without impacting the price? Yes, there is! The solution is Rheocasting. It is “just” a different melt preparation technology that can deliver 130 to 160 bars of helium tightness with the proper measures taken.

Take a closer look at the Rheocasting Expert on Demand when you want to take over the business for millions of compressor housings per year. Schedule a Free Consultation Call for more information about the F-Gas ban and Rheocasting!