Throughout last couple of years, AS CASTING has implemented iTherm® shot block into their production and reached substantial productivity improvements, based on shorter cycle time and longer component lifespan.
shorter cycle time
With 5 casting machines ranging from 400 - 1000 t, they supply parts up to 13 kg to both domestic and international customers in the electrical and automotive industries. Their goal was to optimize the performance to the extent where the die or its components are not limiting the cycle time reduction.
The initial comparison of conventional and iTherm® shot blocks has shown, that conformally cooled iTherm® shot block should bring a good optimization of the cooling speed and a more even heat distribution across the working surface. As a logical consequence of better thermal management also a longer lifespan was expected.
The highest temperature difference between conventional and iTherm® blocks was expected in the area that is in direct contact with molten aluminium.
After reducing the cycle time by 4,5%, to 52 seconds, it became clear that there was more potential for cycle time reduction. Based on that, the second version of the shot block has been developed. By upgrading conformal cooling arrangements (cross-section, shape) the flow rate was improved by 56%, without any adjustments to fluid velocity.
Both of the iTherm® shot blocks are still in operation and have surpassed the lifespan of conventional shot block by more than 2 times.
By implementing the iTherm® conformal cooled shot blocks in their production, AS CASTING has improved two of the most important areas in HPDC, cycle time and component lifespan. Based on close engineering and R&D cooperation between AS CASTING and HTS IC, a fully customized iTherm® shot block was developed to meet the exact productivity optimization goal.