Fully automated test facility on an industrial scale for the development of complex die-casting components made of aluminium and magnesium materials as well as for process and material development
LKR is expanding its industrial related casting research portfolio by the start-up of a new cold chamber high-pressure die casting machine (FRECH K-DAK1100 type). In order to work under quasi-production conditions the fully automated casting unit from FRECH is equipped with all necessary peripheral devices:
- Hindenlang KLEM 1200 crucible furnace with a capacity of max. 1.000 kg
- Meltec AVDL linear dosage system with a capacity of 1 - 5 kg and 5 - 20 kg
- Wollin spray device
- Robamat mould tempering units for heating and cooling
- KUKA cast part-removal and -insert robot
The cold chamber die casting machine with a horizontal casting unit will be applied for casting of aluminium and magnesium parts up to 20 kg in industrial scaled research projects. At a clamping force of 12.000 kN and at a mould height of max 1.2000 mm it will be possible to cast vehicle structural cast parts. In 2019 the plant was extended by a Magnesium melting and dosing equipment.
LKRs research work is actually focused on Aluminium and Magnesium alloy development and on the process development respective process optimization. New mould temperature control techniques like near-surface cooling, enabled by additive manufactured mould inserts, temperature control units and by innovative mould spraying techniques will be investigated. This research will lead to improved mould lifetime and shorter cycle time.