Cost Savings Achieved by Redesigning Sand Casting Part as Die Casting Part

Problem: A manufacturer of geothermal power units experienced problems with a sand casting part. Issues included excess material, high casting cost, high machining costs and slow production time.

Solution: Rheocast engineers worked with the customer to help them redesign the part, converting it from a sand casting to a die casting component. The resulting part had thinner walls, required less machine stock, reduced machining costs and generated faster cycle times. The customer achieved substantial savings: machining time, casting weight and assembly time were all reduced by 83% on average. In addition, the Rheocast die casting component was part of an entirely American-made product. This project also received industry recognition, winning the International Die Casting Competition hosted by the North American Die Casting Association (NADCA).

The Rheocast Advantage 

Most die castings are made using nonferrous metals such as aluminum, zinc, brass, copper and magnesium. High-pressure die castings offer many advantages over other manufacturing processes. Die cast components are stronger, lighter in weight and require less machining than fabricated parts. Complex and intricate shapes can be die-cast in a single homogenous piece which eliminates assemblies and welding.

Rheocast specializes in cold chamber aluminum die casting and brass die casting. Aluminum and brass alloys produce highly repeatable, complex shapes and at very competitive prices. Each alloy category offers its own unique benefits. Here are some of the advantages of using brass and aluminum alloys for your die castings: