Switching from machined RF shields to precision die castings let Anritsu Co., Morgan Hill, Calif., cut costs in its Site Master series of analyzers, which are made in small lots. The company estimates payback on its die-casting investment will take only six months. “Most of these components are produced by traditional machining from plate or bar stock,” explains Anritsu Process Engineer Sam Krull. “Because we’re a lowvolume manufacturer, we sometimes don’t have the opportunity to use less-expensive production techniques. But we’ve seen payback in these parts in as little as three months.” Anritsu worked with Alloy Die Casting Corp. (ADC), Buena Park, Calif., to develop the A380 die-cast aluminum parts. “The shields are fairly complex, which makes some casting houses shy away from smaller production runs,” says ADC Design Engineer Gary Gray. “Some shields are just 0.03- in. thick. And any time an alumnum casting gets below 0.06 in., you can run into complications. So it’s important to get the right balance of injection speed and venting capacity, as well as precise temperature control.” The shields are cast from single- cavity tools, typically on a 250-ton press. The molten 1,200°F alloy goes through a small 2-in. plunger that fills the die in about 25 msec. The process, however, maintains a relatively low gate velocity, around 1,200 ips. Depending on the type of shield, shot sizes range from 4 oz to about a pound. “We typically run at a conservative speed of 70 and 80 cycles/hr,” says Gray. “We want the injection to be fast enough to fully atomize the material and give us a quick fill time. But we have to temper that with the understanding that higher gate velocities erode tool steel more quickly and can shorten die life.” Finishing operations for the shields include straightening and about 6 min
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Ingots and Casting Stock
Ingots and casting stock are metal and alloy product forms designed for foundry work, die casting, investment casting, and other metal casting applications.
Metal Casting Services
Metal casting involves the shaping of free-flowing liquid metals through the use of dies, molds or patterns.
Metal Castings and Cast Stock
Castings and cast stock are metals, alloys, polymers and other materials that are cast into bar, rod, angle, channel, tee, or other shapes.
Cement, Concrete, and Mortar
Cement, concrete and mortar are polymer or cement-based binders, compounds or aggregate mixtures for joining components and forming structures.
Insulated Gate Bipolar Transistors (IGBT)
Insulated gate bipolar transistors (IGBT) are bipolar transistors with an insulated gate. They combine the advantages of the bipolar transistor (high voltage and current) with the advantages of the MOSFET (low power consumption and high switching).
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