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Rheocasting by SAG - The semi-solid casting process has significant advantages

Fabian Hofstätter from the market leader SAG shows us interesting examples.

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Thomas Fritsch, Chief Editor

The special casting process in which aluminum is cast in a semi-solid or semi-liquid state, so-called rheocasting, seems to be in vogue at the moment and there are good reasons for this.

Only recently at the Aalen Foundry Colloquium we met Fabian Hofstätter from Salzburger Aluminium AG (SAG), who gave an interesting talk on the subject.

We are particularly interested in the advantages of the process and which components are specifically suitable.

With regard to the advantages of rheocasting, several major focal points immediately stand out, which are of utmost importance for aluminum components.

Air reservoir finished product (requirement: helium-tight welded) Copyright: SAG, Fotografin: Karin Pasterer

 

Optimum mechanical strength and elongation

Area of application: vehicle components, chassis parts, chassis-relevant components

Up to 60% less weight

Compared to steel parts, higher fatigue strength, ideal for automotive applications

Excellent weldability and compressive strength

Application range: vehicle components, chassis parts, pressure vessels, coolers, pumps

Best thermal and electrical conductivity

20% higher thermal conductivity Application area: telecommunications, battery technology, line electronics

No post-processing necessary

Cost effective as no milling, deburring or grinding required. Applications: Visible components, interior parts, brake discs.

Rheocasting cover for air reservoir (requirement: helium-tight weldable also on cast skin)
Copyright: SAG, Fotografin: Karin Pasterer

 

Full freedom of design

Different wall thicknesses possible, high functional integration in the field of bionics. Weight optimization with the same installation space

In summary, it can be concluded that amazing results can be achieved with the rheocasting process. The high strength and ductility, very good weldability and conductivity of rheocasting components enable efficient lightweight construction in many areas. Less weight leads to more range and lower energy consumption. Rheocasting can thus contribute to CO2 emission reduction with considerable weight savings. More efficiency in the production process: Rheocasting can avoid costly reworking of castings. The engineers at SAG were the first to industrialize the rheocasting process and today also offer large series of up to 400,000 parts.

Among the impressive components Fabian Hofstätter presented in his paper in Aalen were helium pressure-tight components, air spring tool systems. For these components, the low porosity of the material, the strength and the outstanding mechanical properties are particularly important.

If you would like to take a closer look at this topic or ask the SAG experts questions directly, you will soon have the opportunity to do so in Munich at the IAA Mobility 2023 from 5 September to 10 September 2023.

Meet the SAG experts in Hall B1/E 20!

Innovative, sustainable, international

SAG is an internationally active company with Austrian roots. Thanks to highly trained employees, tank solutions and lightweight components for vehicle construction are developed and produced at a total of 10 locations in Europe, Mexico and the USA. The R&D know-how as well as the product and service portfolio are constantly being expanded. SAG is a technology leader in many areas of the materials sector and in the field of cryogenic tanks.

Aluminium brings lightness to vehicle construction. Due to its low weight and corrosion resistance, it has excellent mechanical properties. In addition, it is extremely versatile, 100% recyclable without any loss of quality and thus a very resource-saving raw material.

SAG is the world market leader in the field of rheocasting.

The Salzburger Aluminium Group has been successfully supplying international customers with its innovative quality products for many years - from the automotive, railway and aviation industries to the energy sector.

 

Company Info

Salzburger Aluminium Group

Lend Nr. 25
5651 Lend
Austria

Telephone: +43 / 6416 / 6500-0

Email aluminium(at)sag.at
Web: http://www.sag.at

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