Consistent heating of the mass channel

hotcast Die-casting Nozzle Heaters
hotcast Sprue Nozzle

For ap­pli­ca­tions in the foundry in­dus­try (e.g. hot cham­ber die cast­ing) hotset of­fers a wide range of products.

The hot­cast closed noz­zle heater (GMH) en­ables uni­form heat­ing of the melt chan­nel and has an ex­treme­ly long ser­vice life.

By us­ing the ZD 50/80 and ZD 125 sprue noz­zle for zinc die cast­ing, the melt­ing point is po­si­tioned di­rect­ly in front of the part­ing line by de­sign. The sprue is thus sig­nif­i­cant­ly re­duced. The cy­cle time is re­duced by up to 40% and, at the same time, the raw part qual­i­ty increases.

The hotcast die heater enables uniform heating of the melt channel and is used in foundry applications.

hotcast Die-Casting Nozzle Heaters
(type GMH and OMH)

The hotcast die heater enables uniform heating of the melt channel and is used in foundry applications.

Based on heat­ing with a hot­spring Maxi with pow­er dis­tri­b­u­tion, the hot­cast closed mouth­piece heater (GMH) of­fers the pos­si­bil­i­ty of uni­form heat­ing of the melt chan­nel. In ad­di­tion to re­sis­tance to pen­e­trat­ing ma­te­r­i­al, the all-round weld­ed closed sys­tem en­sures a high lev­el of en­er­gy sav­ings (up to 60% com­pared to tra­di­tion­al car­tridge heater heat­ing) as well as short­ened cy­cle times com­bined with a high po­ten­tial for ma­te­r­i­al sav­ings (short­ened sprue pin and short­er cy­cles due to deep im­mer­sion in the mold).

The hot­cast open mouth­piece heater (OMH) of­fers a low-cost al­ter­na­tive to the closed system.

hotcast Sprue Nozzle

With the hotcast sprue nozzle, the cycle time in zinc die casting is reduced by up to 40% and at the same time the raw part quality is increased.

  • Up to 40% re­duced cy­cle time with high­er part quality
  • Up to 30% less shot weight
  • Up to 7% in­crease in part weight due to high­er mi­crostruc­ture density
  • Op­ti­miz­ing the flowa­bil­i­ty of the ma­te­r­i­al, thus low­er poros­i­ty and few­er shrink­age cavities
  • con­tin­u­ous heat­ing from the cast­ing neck in­to the mold
  • po­si­tion of the de­po­si­tion point di­rect­ly in front of the part­ing line
  • elim­i­na­tion of the sprue cone
  • re­duc­tion of mold costs
  • more de­sign free­dom for new molds, e. g. e.g. for small­er chan­nel cross-sections
  • less scrap, es­pe­cial­ly for fin­ish­ing, e.g. electroplating
  • pos­si­ble to re­place cold bush­ings in ex­ist­ing molds
  • suit­able for ma­chines with 50 t, 80 t or 125 t clamp­ing force

Improves cycle time with a smaller sprue

With the hotcast sprue nozzle, the sprue is reduced. This results in significant material savings, lower mold costs and shorter cycle times by up to 40%.

The new hot­cast sprue noz­zle is po­si­tioned di­rect­ly in front of the part­ing line, like the usu­al cold bush­es. This shifts the melt­ing point di­rect­ly in front of this part­ing line and the sprue is re­duced to a min­i­mum. Sig­nif­i­cant ma­te­r­i­al sav­ings, low­er mold costs and short­er cy­cle times due to faster cool­ing of the melt are part of the cal­cu­la­ble ben­e­fits. Tests have shown cy­cle re­duc­tions of up to 40%. 

Improved component quality due to higher flow characteristics

The use of the hotcast sprue nozzle allows better formed cavities, longer flow paths in the mold and smaller channel cross-sections in the mold design.

The length of the flow path of the melt from the ex­it point from the ma­chine noz­zle is de­ci­sive for the mold­ed part qual­i­ty that can be achieved. Due to the short­er flow path when us­ing the sprue noz­zle, the melt is still at a high­er tem­per­a­ture near the cav­i­ty than with con­ven­tion­al process­es. This means that the cav­i­ty can be shaped bet­ter or longer flow paths can be pro­vid­ed in the mold. At the same time, small­er chan­nel cross-sec­tions can be tak­en in­to ac­count when de­sign­ing the mold.

Less scrap after finishing

With the hotcast sprue nozzle, the cycle time in zinc die casting is reduced by up to 40% and at the same time the raw part quality is increased.

Due to the im­proved flowa­bil­i­ty, the formed cast­ing has a denser mi­crostruc­ture. Con­sis­tent­ly high mold­ed part qual­i­ty is achieved in se­ries pro­duc­tion thanks to re­duced poros­i­ty and few­er shrink­age cav­i­ties. Tests show that there is sig­nif­i­cant­ly less scrap on sur­face parts. Such sav­ings have a par­tic­u­lar­ly pos­i­tive ef­fect if scrap can on­ly be de­tect­ed af­ter fin­ish­ing mea­sures, e.g. elec­tro­plat­ing.

The use of the sprue noz­zle has a fur­ther pos­i­tive ef­fect on the ser­vice life of molds and ma­chine com­po­nents. With iden­ti­cal fill­ing be­hav­ior, the ma­chine can be run at low­er cast­ing pres­sure. The ma­chine pa­ra­me­ters “fill­ing speed” and “fill­ing pres­sure” can be re­duced with­out chang­ing the qual­i­ty of the components.

hotcast Sprue Nozzle in action — Siku crane

hotcast heating system from casting neck to sprue - example SIKU

Well-known com­pa­nies al­ready use the sprue noz­zle. Dr. Chris­t­ian Kuw­er, tech­ni­cal man­ag­er of Sieper GmbH in Lü­den­scheid, Ger­many (man­u­fac­tur­er of SIKU toy mod­el cars and WIKING mod­els) has ap­plied it and comes to the con­clu­sion: “We have found with one of our ‘prob­lem molds’ that we can now re­pro­ducibly man­u­fac­ture the cast­ing-tech­ni­cal­ly dif­fi­cult com­po­nent, which we pre­vi­ous­ly could on­ly pro­duce with great dif­fi­cul­ty in an ac­cept­able qual­i­ty, in very good qual­i­ty. ”

Fur­ther, Dr. Kuw­er con­firms, “Fill­ing speed and fill­ing pres­sure can be re­duced with­out any dis­ad­van­tages for the qual­i­ty of the components.”

Heating system from casting neck to sprue

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