Reducing customer scrap rates using technology

Leaky Castings, Leaky Profits

A team of vendors dedicated to success allows custom die caster to focus on production

Plagued by leaking castings

A custom die caster needed help producing a high-volume front cover casting, that was plagued with high scrap rates and impregnation costs.

Elba Tool and Magma were contacted to propose modifications that would reduce or eliminate problems caused by excessive porosity.

Analyzing the problem

After several iterations of analyses the shrinkage porosity was significantly reduced. Part geometry modifications would be required to eliminate or reduce the remaining porosity.

Elba Tool modified the part model and 3D part geometry was submitted for approval by OEM prior to proceeding

Design validation using technology

Running process simulations again showed a significant reduction in porosity and hot spots. Although not completely eliminated, analysis of the data showed the results to be more than acceptable

Dies were redesigned with new casting and gating geometry and built accordingly. Cooling was placed strategically, and manifolds with valves were added to the tool to allow adjustments as conditions dictated.

Successful results!

Initial sampling showed the following results:

  • Reduction in cycle times in excess of 20%
  • Scrap rate reduced to less than 1%
  • Impregnation of castings eliminated
  • Dimensional repeatability and bending of castings much improved or eliminated

Collaboration through partnerships

A strategic partnership with Elba Tool and it’s team of qualified vendors helped achieve superior results through technology and expertise allowing our customer to focus on production.

Elba Tool has the knowledge and working relationships with vendors in place to help you achieve success. If you have a problem that has been difficult to solve, or don’t have the time to address it, let us know and we can help you increase efficiency and profitability.

More Projects
Our Services

Get Started

Do You Need a Precision Machining Partner that truly Performs for you?

Innovation and technology means helping you increase productivity and profitability to remain viable in today’s global environment.