HFEMDC®︎ | Technologies

The Basics of Aluminum Casting

The Melting and Casting Basics

Clean, molten aluminum is poured quickly, quietly without turbulence, and solidifies quickly.

Molten aluminum being poured late with contaminants and turbulence, and slowly solidified.

We developed HFEMDC🄬 in pursuit of the basics of casting technology, which are cleanly molten aluminum-the foundation of aluminum melting, and quick, quiet, unruly pouring and quick solidification-the core of aluminum casting.

General Mold Casting Processes

GDC＝重力鋳造法 — A casting method that molten aluminum is pressurized by gravity and poured into a mold.

LPDC＝低圧鋳造法 — A casting method that pours molten aluminum into the mold using air pressure.

HPDC＝高圧鋳造法（ダイカスト法） — A casting method that molten aluminum is injected into the mold by a hydraulic cylinder at high pressure and high speed.

Advantages and Disadvantages

Feature 1:Pouring quickly, quietly, and without turbulence

We have been looking for a new method of pouring that does not depend on pressure. We focused on electromagnetic force and stared testing pouring molten aluminum using the force.

Eddy currents are generated by 3-phase alternating currents, with the influence of Lorentz force creating the motion of molten aluminum.

Video：The connection between electromagnetic pump and the mold
Test video: Pouring the molten aluminum

Feature 2:Quick Solidification

＊Conventional coating agent

溶けたアルミニウムの金型への保護と充填性向上のため保温性のあるセラミックを金型へコーティング金型の保護や溶けたアルミニウムの充填性を担保することと溶けたアルミニウムを急速に凝固させることは相反する事象でした。

＊Inorganic Powder Mold Release Agent

“To enable fast solidification, molten aluminum should have direct contact with the mold, and then the mold must be rapidly cooled.
However,
in gravity casting and low-pressure casting, direct contact with the mold is not allowed as it accelerates the deterioration of the mold.”

In order to break through this contradiction, we have established the electrostatic application of inorganic powder mold release agent, which combines improving the flowability of molten aluminum with electromagnetic pump. Now we are able to achieve an ideal casting process.

得られたメリット塗装厚みを極限まで下げられるため熱抵抗が低下し鋳造凝固時間短縮凝固時間が短縮する事で、製品１個当たりの製造時間も短縮生産効率が向上して、より少ないエネルギーで製造することができます。

By combining the electromagnetic pump and inorganic power mold release agent, we succeeded developing products with both high performance and high quality.

アルミニウムの組織サイズが微細化したことで、
従来の製法に対して製品素材の機能が向上しました。