MR2 Casting Solutions

This innivative idea was sparked based on an inspiration from my visit to Aalen University in the year 2001 wherein Dr. Professor Friedrich Klein took me on University tour.
During that time could experience 3 Dimensional Scanned part projected in a room. The beauty of the matter is that you can directly walk inside the part and measure the porosity if any entering in to the pore. Then while witnessing the project work by research scholars, had come across a part of 1000mm long, 500mm wide and 1mm Thick diecast. The initial trial parts were spread in a room with 10 Stages filling. 10%, 20%,......100% Full shot. The surprise was no overflow pads. Only venting.
That is what helped to achieve this 0.9mm part as first time right success.
This part is for suspension assembly. Has post operations like Vibro-finishing tumbling and Heat Treatment. Yes after HPDC process we did Vibro-finishing and Heat Treatment.
The alloy is Silafont 36 structural aluminium.
Quite an inspiration.

The satisfaction is engineering arena, High Pressure Diecasting a component having 0.9mm (In Europe 0,9mm) component with 2 cavity tool taking prototype.
It doesn't stop there. Make it multi cavity. Produce and supply with bent it like Beckham tolerance with +/- 0.2 mm at 200+ mm diameter.
It was destined to be failure by most of the team members and customer also having doubts.
But it was successfully done in prototype within 17 days (believe it is 17 days)
Mass production is a history that 2 cavity 150 shoots per hour in a 500T machine.
This is called the diecasters pride.
I love it.
The challenges are to be met and conquered.
By the way earlier the part was a sheet metal.

During a business trip had a window of opportunity to visit Great Wall Of China
During December 2017

Methods
Moulds
Match Plate
Melting
Machine
Maintenance
Man Power
All should be aligned towards the Mission

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrousmetals, specifically zinc, copper, aluminium, magnesium,lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Casting
SG Iron
Sand for Mould
Sand for Core
Pattern
Core Box
Design
Simulation
Pattern Making
Core Box Making
Core Shooting
Melting
Casting Pouring
Shake Out
Trimming
Shot Blasting
Painting
Great opportunities for Cost Optimization, Cost Reduction, Productivity Increase, Operational Efficiency, Rejection Control and Innovative Process Re- Engineering!

Training at LGB on Diecasting Basics!

It was a great meeting looks at a bright future together!

An appreciation from one of MR2 Casting Solutions - The great Mr. Elengo - Managing Director - M/s. Raltor Metalltechnik.

Looking forward to the visit to Bangalore tomorrow by this time! To meet with one of MR2 client for the visit of German Firm, Italian Customer from China! India, China, Italy and Germany! What a deadly combination!

Working out a proposal to collaborate with a GDC company for reaching Goal 2020! With minimal investment and maximum returns!