BÖHLER die Casting Concept

The BÖHLER Die Casting Concept (BDCC) is an approach developed by voestalpine BÖHLER Edelstahl together with its customers to optimize the die casting process. This concept takes into account all factors affecting die casting, from material engineering to production and economic aspects.

The BDCC was created to meet the growing needs of the automotive industry and other sectors that use components made by die casting. As demand for more complex and larger components has increased, it has become critical to develop innovative solutions to ensure the quality, efficiency and competitiveness of the die casting process.

Through BDCC, voestalpine BÖHLER Edelstahl actively collaborates with its customers to develop and implement tailored solutions that optimize the die-casting process, improve material performance, and meet the specific requirements of each application. In addition, by reducing the weight of components made by die casting, it contributes to lower CO2 emissions, making the BDCC approach also environmentally sustainable. In this way, BDCC helps ensure efficient, sustainable, and high-quality production of die-cast components.

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Beyond molds: the evolution of die casting

“Beyond Molds: the evolution of Die Casting” è stato il titolo di un evento dedicato al mondo della pressocolata che ha visto la partecipazione di 60 persone al Kilometro Rosso Innovation District di Bergamo.

Luca Bonvini, Böhler’s Technical Manager Italy together with Harald Wurmbauer, Böhler’s Technology Hot Work Steel, outlined the main features of the BÖHLER Die Casting Concept (BDCC), highlighting the potential benefits that could be gained from optimized use of materials in terms of quality and performance.

“L’industria della pressocolata deve far fronte a richieste sempre più esigenti, con la produzione di componenti complessi e di grandi dimensioni, soprattutto nel comparto automotive”, ha spiegato Luca Bonvini. L’obiettivo di ridurre le emissioni di CO² impone infatti la ricerca costante di riduzione del peso dei veicoli, a cui può contribuire l’impiego di componenti in alluminio da pressocolata.

“In the high-pressure die casting market, we see a trend of increasing numbers of components for electric mobility as well as foundries that may invest in Giga presses with the goal of producing the entire front or rear chassis of a car in one piece,” Bonvini said.

To meet the changing needs of the market, voestalpine HPM Italia offers the BÖHLER Die Casting Concept (BDCC), a state-of-the-art approach developed by the company in cooperation with renowned foundries and moldmakers.

The main key points of the BÖHLER Die Casting Concept are as follows:

– Analysis of customer project conditions to define a customized solution

– Collection and analysis of process parameters ( material, time and temperature, cooling system and HPDC process parameters)

-defining the best balance of material properties to achieve the best performance of the HPDC process

-performance enhancement with innovative solutions – coating and/or additive manufacturing

Integrated approach to optimize mold life

The second part of the meeting was dedicated to the presentation of a case study conducted by Enea Colombo, Giga Tool Program Manager of Costamp Group, host company of the event, in which he presented from a design point of view the challenges that the design and optimization of a Giga mold can entail and the multiple variables that the manufacturer must take into account in order to offer the customer a mold and subsequently a performing process.

Costamp Group is a top manufacturing company in the design, engineering and production of molds for automotive components. With over 50 years of history, it is able to provide a complete offering in terms of processes (HPDC, LPDC & Gravity, Plastic) and products (aluminum, magnesium, cast iron, plastic).

Infine, Herbert Horinek, Engineered Products – Specialist Die Casting di voestalpine High Performance Metals, ha approfondito gli Engineered Products per il Die Casting e l’High Pressure Die Casting Cost Saving Calculator.

“The voestalpine Die Casting System is an integrated approach to optimizing tool life through the use of superior tool steels, optimal heat treatment methods, application of PVD coatings, and state-of-the-art additive manufacturing,” Horinek explained.

The final panel discussion was attended by experts from the foundry and die casting industry, who shared their experiences and discussed the future challenges and opportunities of die casting.

Short Video Event: https://youtu.be/Ms2gfRW_ieA

Die casting seminar – CSMT innovative contamination hub of brescia

A Webinar entirely dedicated to the die casting industry, in which we discussed the Bohler Die Casting Concept (BDCC) and the new frontiers of the die casting industry in Italy, watch the recording at the link: https://youtu.be/aLxJ8ZxirXY