What do you know about Rheocasting?

Rheocasting solutions and parts are presented at any conference nowadays. Rheocasting isn`t new. It was invented by Prof. Flemming in the 1970s. Many companies used Rheocasting parts for some time before returning to HPDC. So, why do we hear about it everywhere?

It wasn`t a mainstream topic until recently because it wasn`t needed. HPDC parts were good enough for each application. But now, the foundry industry has reached the limits of HPDC as we know it.

1. We see megacastings with shot weights over 100 kg. 100 kg of hot liquid metal passes over the ingate section. This drastically limits the lifetime of the tool and plunger. In addition, after over 2.5 meters of flow length at the end of the filling, the melt fronts must recombine to reach high elongations. This requires so much effort and money that “easier” solutions are needed.
   
   
2. Electronic components are becoming increasingly powerful. With that increase in computational power comes an increase in thermal power. This waste heat has to be moved away from the electronics into a cooling medium to prevent the circuits from failing. So, we need high-heat conductivity alloys that cannot be cast in HPDC.
   
   
3. We see new castings, like battery boxes, that require a certain leak-tightness. Impregnation is the norm to get your HPDC part leak-tight. This is quite expensive and not possible in every area. For example, if you want to weld your battery box shut, the plastic sealant melts and drops into the battery.
   
   
4. We see old parts that had to undergo legislation that introduced changes. In order to get cool air in your car, you need a compressor and a heat exchange system. The gas in these systems has to be changed to propane or carbon dioxide. These are smaller molecules and can still pass through the impregnation. Many car makers are now switching to forgings for a multiple of the price of an HPDC casting. Rheocasting can deliver leak-tight compressors at over 150 bar of helium pressure. So, you maintain the low cost and high efficiency of the HPDC process.

After reading this article, you will understand why Rheocasting became an important topic in the following decades. Now, it`s up to you to educate yourself on that topic. Click on the link and take the quiz to see if you are already a Rheocasting Expert.

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