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PTC for Aluminum gravity die-casting (GDC)

Cylinder Heads

Brake Systems

Pistons

Other Parts

Gravity die casting is a common technique for automotive parts casting where high mechanical properties of the mass production part are required. For example: Cylinder Head, Brake Caliper, Piston, Muster Cylinder etc.

These y automotive parts have complicate casting shape which required efficient fiddling during the solidification

The risers supply the required feeding to avoid shrinkage and porosity defects

The PTC process reduces the risers' mass dramatically by creating efficient stirring during the solidification, solves the casting problems and improves quality.

The PTC process stirs the metal during solidification thus improves foundry yield, productivity and product quality

PTC Advantages in Aluminum gravity die-casting (GDC) Parts:

	Production cost reduction of GDC by 20%-25%
	Riser's mass reduction by 70% -90% and thus casting weight reduction by 35%
	Foundry yield increase from 50% to over 80%
	Foundry productivity increase by 20%- 25%
	Melting and Holding furnaces efficiency increase by 50%
	Environmental emission reduction by 35%
	Metal feeding improvement
	Shrinkage and porosity elimination
	Mechanical properties improvement
	Microstructure refinement
	Surface quality improvement

As a result significant production cost savings and product quality improvement is achieved

The PTC process has been tested commercially by several automotive and automotive subcontractor foundries, for aluminum gravity die casting (GDC) . The foundries confirmed the benefits and efficiency of the PTC stirring effect during Aluminum gravity die-casting (GDC).
Using the PTC process to stir the molten metal during the solidification significantly reduces the risers' mass by 70%, saves 35% of the casting weight and increases casting productivity on existing lines.
The PTC process improves cast part quality, reduces shrinkage and porosity. The fine microstructure that has been achieved by the stirring effect of the solidifying metal improves dramatically the mechanical properties of the cast part.
The PTC has several environmental benefits, The risers` mass reduction decreases the amount of waste material that needs to be recycled.

GDC of Brake systems

The PTC process has being successfully tested and applied on Master cylinder and Brake Caliper. For both parts it saves risers mass, 90% for the master cylinder and 70% in the brake caliper. It reduces the porosity defects ratio and improves feeding. In the master cylinder it may allow casting cylinder with thinner walls that will require less machining. Machining is the most costly part n the master cylinder's production. The PTC improved feeding allows casting thinner walls. In the case of brake caliper it will allow casting lighter calipers with 8 mm walls instead of 12 mm.

PTC Advantages in Aluminum gravity die-casting (GDC) of Cylinder Heads

	Production cost reduction of GDC cylinder head by 20%-25%
	Riser's mass reduction by 70% -90% and thus casting weight reduction by 35%
	Sand mass core reduction by 40%
	Foundry yield increase from 50% to over 80%
	Foundry productivity increase by 20%- 25%
	Melting and holding furnaces efficiency increase by 50%
	Foundry sand reclamation reduction by 30%-40%
	Environmental emission reduction by 35%
	Metal feeding improvement
	Defects ratio reduction
	Shrinkage and porosity elimination
	Mechanical properties improvement
	Microstructure refinement

As a result significant production cost savings and t in product quality improvement is achieved.

The PTC process has been tested commercially by several automotive and automotive subcontractor foundries, for Aluminum gravity die-casting (GDC)–of cylinder heads. All foundries confirmed the benefits and efficiency of the PTC stirring effect.
Using the PTC process to stir the molten metal during the solidification creates metal flow into the solidifying part. The metal feeding reduces the riser's height and weight by 80% and reduces sand top core and binders by 35%. PTC increase casting p productivity on existing lines.

The finer microstructure that has been achieved by the stirring effect of the solidifying metal, improves dramatically the mechanical properties of the cast part.
PTC stirring effect reduces the production cost of GDC cylinder head by 20%-25% and improves the quality of the castings.

The PTC has several environmental benefits. The risers` mass reduction decreases the amount of waste material that needs to be recycled and sand binders that are used. Sand binders reduction decreases the amount of toxic gases that been released during the casting process.

The PTC can be applied on any type of aluminum alloy.
The PTC is add on technology and can be integrated on any casting line.

The data presented on the website is limited due to confidentiality


Casting Weight Saving of 35% and Sand Core Saving of 40%
Engine Block GDC - Gravity Die Casting

Conventional casting			PTC casting





PTC allows cast gravity die casting parts with low risers with the same quality as with high risers.








Aluminum metal level in the mold when PTC applied during GDC much lower than in conventional engine block GDC casting

PTC system in Action

Design: Tween-id