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High Pressure Die Casting Plant DAK1100-112

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


Our services:

  • Process related and application-oriented alloy development
  • mechanical and thermodynamic material characterization
  • metallographic analysis and evaluation
  • component development/simulation/design
  • process development and associated Process simulation
  • tool development as well as test operation of tools
  • component prototyping/pre-production
  • provide plant capacities (rental option)
  • holistic solutions from the idea to the serial-compatible component

    Technical Data:

    • Oskar Frech GmbH & Co. KG
      locking unit
      • locking force: 12.100 kN
      • mould height: 400 – 1.200 mm
      • mounting plate: 1630 x 1630 mm
      • max. casting area: 1.692 cm²
        casting unit
        • max. casting force.: 1.120 kN
        • shot position: 0 - 420 mm
        • casting stroke: 750 mm
        • injec. plunger diameter: 80 - 140 mm
        • max. component weight: 20 kg
          • ejector force: 559 kN
          • ejector stroke: 230 mm
          crucible furnace
          • Typ KLEM 1200
          • melting capacity up to 1.000 kg Al
          • Meltec vacuum dosing system (5-20 kg)
          • Wollin spraying unit PSM3
          • Robamat heating/cooling units
          • KUKA Loading and unloading robots

          The high-pressure die casting process

          In the High Pressure Die Casting process (HPDC), the liquid casting metal (i.e. aluminium or magnesium alloys) is pressed into a steel mould by a piston at very high speed and under very high pressure. The filling time is between 0,2 and 0,4 seconds and the specific casting pressure can be up to 1000 bar. In the cooled mould the metal solidifies very quickly, and the casting part can be removed after a relatively short cooling period.

          The process is carried out automatically and thus offers a maximum productivity. The high mould costs are calculated for large quantities, which is nearly always the case in the fields of HPDC application (automobile construction, mechanical engineering, equipment technology, etc.).