Case study on quality improvement of aluminum castings for handling products from other companies.
AC4CH/AC4C/AC4B/AC4A/AC2A and other 10 aluminum alloys (countermeasures for casting defects and air leakage in products from other companies)
An 80% defect rate at other companies, with continuous issues of casting defects and air leaks. By changing the core sand and improving the mold coating, we reduced it to below 3%. Prototyping from one piece, with a track record of 5,000 items across 200 companies.
We received an inquiry regarding aluminum castings that were being cast by another company, where casting defects appeared on the machined surfaces, and leaks could not be stopped during the airtightness test. The defect rate reached 80%, and they were casting multiple times the necessary quantity to secure good products. In castings with internal passages, the cores that shape the passages can sometimes cause casting defects. Gases generated from the cores due to the heat of the molten metal can become trapped inside the casting, appearing as holes on the machined surfaces and creating pathways for leaks. Simply changing the casting conditions will not stop this type of defect. Karmo Casting reviewed the drawings and defective products, narrowing down the causes to the cores and the surface of the molds. We proposed changing to core sand that suppresses gas generation and improved the coating applied to the surface of the molds. We conducted everything in-house, from casting to machining and inspection using a three-dimensional measuring machine, reducing the defect rate from 80% to below 3%. The switch can be made after confirming quality with a single prototype, and factory tours before the contract are also possible. We are offering a free guidebook summarizing the causes and countermeasures for casting defects such as casting defects, poor flow, and cracking. Please download it from the link below.
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basic information
【Scope of Contract】 Production of wooden patterns and cores / Casting / Machining / Integrated production of inspection (processing of cast products from other companies is also acceptable) 【Defects Addressed】 Casting defects and air leaks (countermeasures through changes in core sand and improvements in coating) 【Lot Size Supported】 From 1 piece (switching after quality confirmation in prototype) 【Casting Size】 50mm square to 1,000mm square / Minimum thickness 1mm (local) and 1.5mm (overall) 【Materials Supported】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 【Casting Processes】 In-house possession of five methods: sand mold / self-hardening / alkaline phenolic / cold box / metal mold 【Machining Equipment】 15 units of 5-axis machining centers / 2 gantry-type machines / 3 vertical machines / 2 NC lathes 【Machining Accuracy】 Geometric tolerance ±0.03mm 【Inspection Equipment】 2 contact-type 3D measuring machines / Non-contact 3D digitizer (deviation 30-80μm) / 3D scanner NIMBLETRACK Gen2 【Certifications】 ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step2
Price information
If you could inform us of the details of the drawings and the defects (locations of casting defects and leaks, defect rate), we will provide a free estimate along with improvement proposals. If you have the actual defective products, it will be easier to determine whether they originated from the core. If the defect rate decreases, we can also reduce the number of extra castings and rework in processing. We can switch after confirming the quality through prototypes starting from one piece.
Delivery Time
※The prototype will be shipped in a minimum of 2 weeks, and the first order including wooden mold production will take at least 3 weeks. The delivery time for transferred items may vary depending on the content of improvements, quantity, and processing locations, so please let us know your desired switch timing.
Applications/Examples of results
【Applicable Industries】Industrial machinery / Machine tools / Robots / Ships / Railways / Power and energy / Semiconductor manufacturing equipment / Automotive and CASE 【Improvement Case】 ■ Products transferred from other companies (Aluminum castings / Air leakage due to internal casting defects / Change of core sand and improvement of mold coating reduced defect rate from 80% to below 3%) 【Other Achievements】 ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shape with 6 cores) ■ Industrial machinery parts (AC4CH-T6 / Complex shape with 11 cores) ■ Copper alloy castings for power equipment (CAC406 / Thin-walled, internal passages, and uneven thickness measures) 【Used in Such Situations】 - Castings with internal passages that have casting defects on the machined surface and fail airtightness tests - Casting more than the required quantity to account for defects - Even when changing conditions at the casting site, the defect rate does not decrease - Looking for a transfer site for complex-shaped parts that use cores 【Scale of Achievements】 200 companies and 5,000 items in the last 5 years. More than 500 prototype and development achievements annually.
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Company information
At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. Manufacturing has continuously supported the backbone of Japanese industry. At Karmo Casting, we have maintained that spirit and pride, dedicating ourselves to pioneering initiatives in the industry since our founding. Our primary goal is to build partnerships with our customers. To achieve this, we believe it is essential to flexibly adapt to changes in the times and realize all kinds of needs. Our relentless pursuit of technical expertise, responsiveness, quality, and speed reflects this attitude. While sensitively and swiftly understanding our customers' thoughts, Karmo Casting will continue to accumulate tireless efforts and changes as a manufacturing company that is chosen and needed by our customers.
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