In October 2021, Bühler launched the Carat 840 and the Carat 920 with locking forces of up to 92,000 kilonewtons (kN). With these solutions, Bühler’s customers can produce structural castings for automotive body in white assemblies, known as megacastings. This expansion builds on the success of the Carat 560 and 610, which have up to 6,000 tons locking force and have been on the market since 2020.
Nearly a century of experience in die casting
Bühler has been active in die casting for over 90 years and supported customers with thousands of applications. Megacasting is a further development of the structural process (complex, thin-walled parts produced using die casting) which Bühler has driven since the early 2000’s. Bühler’s Carat series is the most successful solution on the market and brings megacasting production to the next level.
Cornel Mendler, Managing Director of Bühler Die Casting, says: “Megacasting is of utmost importance for the entire die-casting industry. Megacasting gives the trend towards structural casting another push by extending the range of applications to complete body sections with the use of the new large Carat solutions with up to 92,000 kN locking force."
With the introduction of the Carat 840 and 920 and its vast die-casting experience, Bühler has further developed its solutions to be able to provide complete cell solutions for ever larger projects. Two Carat 840 die-casting cells will be delivered to Volvo Cars for its factory in Torslanda.
Customer focused innovations
“Volvo Cars is among the first carmakers to adopt the megacasting process. The fact that Volvo Cars has chosen Bühler for two complete Carat 840 cells shows that we have the right products and services for this intensively discussed innovation in the automotive industry,” says Cornel Mendler.
“Especially for such large projects, thinking about the entire die-casting cells from the melting furnace to the handling of the final part is essential. Bühler has the competence to deliver these complete die-casting solutions,” Mendler adds.
Megacasting is considered groundbreaking by many car manufacturers who are moving in this direction or thinking about adopting this trend. Megacastings reduce complexity in production by enabling between 70 to 100 parts to be replaced by a single die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport. Aluminum castings have the potential to be almost CO2 neutral, when using low CO2 aluminum alloys and biogas for the melting furnaces. The aluminum that goes into overflows can be remelted directly and reused in the die-casting cell, thereby avoiding transport and recycling. Thinking a step further, the usage of lighter aluminum parts can reduce the energy consumption of the cars over their entire lifecycle.
Bühler offers the right expertise when it comes to megacasting. “Bühler is the number one solution provider for die casting, offering complete die-casting cells with a full range of services in all relevant regions. As of today, half of all structural casting for automotive body in white production is produced on Bühler machines. With more than 800 machines in operation, the Bühler Carat series is the most popular die-casting solution to produce structural parts,” says Cornel Mendler.