Casting technology at Fraunhofer IFAM: Our plant technology

In the area of casting technology, Fraunhofer IFAM has a broad technology portfolio for a wide range of industrial applications. This includes equipment in the following areas:

• Die casting / Squeeze casting
• Low pressure die casting
• Investment casting
• Gravity casting

Equipment: Die casting

Fraunhofer IFAM has two real-time controlled cold chamber die casting machines with clamping forces of 660t and 290t. As part of the research and development work at the institute, primarily aluminum, zinc or magnesium, but also other technically relevant materials are cast on these machines. In addition to conventional castings, components with integrated cavities, composite and hybrid castings as well as e.g. preforms infiltrated with molten metal are produced.

Bühler SC/N66, die casting plant

Technical data at a glance:

• Clamping force: 660t
• Shot weight: up to approx. 8 kg (for Al)
• Real time controlled
• Melting furnace for aluminum (350 kg) / zinc (925 kg)
• Vacuum support possible
  
• Automatic spraying device
• Measurement and process data acquisition: pressure and temperature

Frech DAK 250-34, die casting plant

Technical data at a glance:

• Clamping force 290t
• Shot weight 0.9 - 3.6 kg (for Al)
• Real time controlled
• Melting furnace: for aluminum (200 kg) / zinc (530 kg)
• Vacuum support possible
• Automatic spraying device
• Measurement and process data acquisition: pressure and temperature

Equipment: Low pressure die casting

For low-pressure die casting, Fraunhofer IFAM has one KURTZ and two TEGISA low-pressure casting systems available, which can be used to cast sand molds (core packages) and permanent molds. With the available combinations of inductive and resistance-heated heating systems, the plants are specially designed to meet the requirements of contract casting research.

TEGISA NDGA 100/51L, Low pressure die casting plant

Technical data at a glance:

• Quick Change System for crucible
• Direct and indirect inductive melting aluminum, zinc, steel, cast iron, brass, copper, salt, (nitrogen atmosphere)
• Melting volume: ~ 55 liters
• Melting power: 100 kW
• Melting temperatures: up to 1600 °C
• Casting pressure: up to max. 1 bar
• Maximum size for molds: 1 000 mm x 1 000 mm x 380 mm
• Process gases: argon or nitrogen

TEGISA NDGA 130/70L, Low pressure die casting plant

Technical data at a glance:

• Quick Change System for crucible Direct and indirect inductive melting aluminum, zinc, steel, cast iron, brass, copper, salt (nitrogen atmosphere)
• Melting volume: ~ 110 liters
• Melting power: 130 kW
• Melting temperature: up to 1,650 °C
• Casting pressure: up to max. 1.0 bar
• Clamping force:60 t
• Core pulls: > 4 pieces
• Mold weight: up to 3,500 kg
• Clamping area upper mold side: 1200 x 1200 mm²
• Clamping area lower mold side: 1310 x 1290 mm²
• Column dimension: 1200 x 1200 mm
• Process gas: nitrogen

Kurtz AL 16-12 SC, Low pressure die casting plant

Technical data at a glance:

• Crucible shuttle system
• Electrically resistance heated crucible furnace aluminum, zinc, salt
• Melt volume: ~ 110 liters
• Melting power: 46 kW
• Melting temperature: up to 900 °C
• Casting pressure: up to max. 1.0 bar
• Clamping force: 32 t
• Core pulls: up to 4 pieces
• Mold weight: up to 3,500 kg
• Clamping area upper mold side: 1100 x 1000 mm²
• Clamping area lower mold side: 2380 x 1540mm²
• Column dimension: 1600 x1200 mm
• Process gas: argon or nitrogen