- Lightweight, to meet the new emission standards
- Conventional low-strength steel
- Use of alternative metals such as aluminum and magnesium, along with similar high-strength steel and alloys
- Addition of new additive manufacturing techniques, 3D print patterns and dyes
- Minimization of casting defects
Traditional casting required topology optimization, 3D printing and investment casting for lightweight and patterned products. Innovation, manufacturer feasibility and easy information can be developed together with Click2Cast 4.0, a casting-simulation environment that promotes quality products and prevents casting defects. It is efficient in topology optimization, predicting casting defects, optimized in-gate location and aerogeneration of risers. It prevents air entrapment, mold degradation and shrinkage porosity. The entire process can be summed up in five steps, thus allowing the supply chain to make quick decisions in applying potential and using the best simulation tools.
2. Miratec water-based coatings
Miratec water-based coatings are especially recommended for automobile applications, and have minimum handling, which allows minimum cycle times and more productivity. They help in increasing yield and productivity with their even coating layer, needed in complex core packages and challenging core geometries. In addition to providing a great surface finish, the coating also prevents casting defects to a great extent such as veining, penetration and gas porosity. It has enhanced refractory properties, short drying time, short manipulation time and cost savings. Though flammable if diluted with certain chemicals, it can be stored and transported easily.
3. Exactcast Mini-riser technology
Steel casting applications use fiber sleeves, leading to casting defects. The slurry sleeves don’t use their full potential to prevent shrinkage defects, thus producing only 30% yield. To counteract this, mini-risers don’t use fiber sleeves for steel casting. Thus, the volume at the riser can be reduced without compromising on feeding performance. The non-feeding material is replaced by exothermic compounds, which maintain the metal in its molten state. Mini-risers are thus efficient in providing high yield, thermal properties and performance in a reduced contact area.
4. Exactcast optima risers
Exactcast optima risers are efficient in foundries, due to their optimization potential. The structure of an optima riser consists of a loose metal part at the nozzle and a rigid pin to reduce fettling costs and to reach a certain breaking point. It comes with a friction less sleeve and a riser cap, preventing particles from falling into the mold during the compaction process. They are fitted with a cover of non-friable material which raises the cycle times of molding systems, prevents casting defects and prevents mold contamination.
Technology in the manufacturing industry provides many process-related advantages over conventional procedures, at reduced cost. With further utilization of resources, manufacturers of castings in India have promised significant increase in material production and reduction in cost, resource consumption, maintenance and servicing.