Case Studies
The following examples demonstrate how our customers successfully exploit MAGMASOFT® in order to realize better casting quality, cost savings or reduction of development times.
Air porosity reduction
WEG is a major electric motor manufacturer in Brazil with captive iron and aluminum high pressure die casting foundries. The die casting foundry was facing a 25 % scrap rate for a two-cylinder compressor. Their client did not accept any porosity on the machined faces of the casting.
In the beginning there was the shot chamber
Producing quality die castings starts with the shot chamber. Melt temperature and pouring speed are only some of the most important parameters that influence the quality of the melt. If mistakes are made here, the most expensive die casting machine will not be able to produce quality components.
Reducing of shrinkage defects in a valve body
Normally it is not possible to avoid shrinkage problems in thicker wall sections in high pressure die castings. This occurs because the feeding pressure cannot compensate for shrinkage once the ingate has frozen.
Solving hard drive housing problems
A medium-sized Japanese foundry located south of Kuala Lumpur in West Malaysia specializes in the casting of hard disk drives for desktop and laptop computers of various manufacturers.
Checking out heat checking
Die casting tooling usually has a limited lifetime due to thermal fatigue cracking or ‘heat checking’ of the die surface, caused by high cyclical thermal loads. The surface of a die is exposed to a rapid increase in temperature as metal fills the die and the casting solidifies. As the die heats up, compressive stresses develop in...
- Die casting
- Casting quality
- Cast component optimization
- Profitability and resource efficiency
- Casting design
- Automotive applications
- Heavy industries and wind power
- Permanent mold
- Cast iron
- Steel
- Nonferrous
- Core and mold
- Tool and pattern making
- Heat treatment
- Microstructure and properties
- Stresses and distortion
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