Die casting for the automotive industry

We supply die casting equipment to major automotive companies and OEM automotive suppliers

Casting light alloy engine blocks

3, 4, V6 and V8-cylinder engine block

To produce the 'right' castings, manufacturers look for flexible die casting solutions that suit their configuration set-ups and meet their quality and volume output requirements. Light alloy engine blocks can be manufactured in many ways: 

  • with machines from 2150 to 4000 tonnes,
  • from rough castings to the finished engine block,
  • from 9 to 52 kg of cast weight,
  • with a single die casting machine or the automated integrated solution.

Our die casting machines and automated cells solutions are designed and manufactured specifically for the engine block application and can include: lubrication with dedicated head, a single robot or two robots, deburring die or saw for the automatic removal of the sprue, loading and handling of inserts (cold or pre heated) secondary or ancillary processing (heat treatment, sanding, deburring), and expertise with die makers to optimise the cycle time and die design.

Other light alloy automotive components

  • Cylinder heads
  • Gearbox
  • Oil sump
  • Clutch housing
  • Steering box
  • Turbocharger body
  • Engine support
  • Intake manifolds
  • Steering knuckle
  • Suspension arm
  • Front and rear
  • Brake calipers
  • Master cylinder

Casting light alloy structural parts

In recent years we have consolidated our experience in the field of the "structural" castings, reconciling new technological requirements such as:

  • High speed shot phase
  • Flexibility and combination variations for closing end and shot end
  • High machine rigidity
  • Vacuum technology

 

The requirements for castings with new characteristics are:

  • Bodywork and safety components
  • Magnesium or aluminium alloys
  • Complex geometry
  • With minimum thickness and wide casting area
  • With the option of thermal treatment
  • High integrity

Die casting magnesium parts

Magnesium die casting has significant advantages, primarily the specific weight of only 1.8 g/cm3 (a reduction of 33% compared to 2.7 g/cm3 aluminium). Once limited to electronic components and portable tools, today magnesium is widely used in the automotive industry with the ability to produce complex castings (and that are therefore also structural and safe), which reduce the weight of the vehicle and thus their fuel consumption.

The 2 separate circuit Italpresse shot end, one for the 1° and 2° phase, and one for the 3°, maintains total constancy and repeatability at different shot stages to ensure quality castings, as well as reaching very high speeds, at around 8 meters per second with the metal. In magnesium die casting the alloy has higher flow characteristics and the castings are often very thin walls: the higher shot rate is therefore a key factor in the whole process.

In some cases, the machines are equipped with a double magnesium and aluminium furnace, to allow for differentiated production and total flexibility.

Our die casting solutions:

IP & IPr Three Platen Die Casting Machines with Toggle

The IP and IPr three platen die casting machines with toggle are available with closing forces ranging from 550 to 4400 tonnes. Our IP and IPr die casting machines are solid, reliable and ensure high productivity cycle times.

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TF Two Platen Toggle Free Die Casting Machines

The TF series of toggle free die casting machines includes a wide range of models with closing forces from 1000 to 5600 tonnes. Our TF toggle free die casting machines are reliable, rigid and flexible.

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Turnkey Fully Automated Cells

Flexible, fully automated work cells for light alloy casting production. We engineer automated work cells for three die casting processes: high pressure die casting, gravity die casting and low pressure die casting.

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Gravity Die Casting

Integrated solutions for the gravity foundry, with complete flexibility and customization, from design to technical support during production.

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Low Pressure Die Casting

Low-pressure die casting machines for the production of complex automotive castings.

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Innovation and Technology

Unlock Industry 4.0 possibilities. From a powerful, next-generation control system for our high-end die casting equipment to augmented reality app and energy saving solutions.

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