Döktaş Manisa performed a project to reduce the part weight of an extension bracket. The goal was to convert the material and the process from a cast iron sand casting to an aluminum low pressure die casting including a T6 heat treatment, while guaranteeing the required specification and mechanical properties.
The bracket used in heavy duty trucks had been manufactured as a ductile iron sand casting. Döktaş was approached by the OEM to evaluate the feasibility of realizing the part in aluminum while maintaining the specifications defined by the customer. After a preliminary analysis and discussions regarding feasibility, an AC 43300 aluminum alloy was selected as the material, and low pressure die casting including a T6 heat treatment was defined as the preferred process.
The main challenge for the Döktaş engineers for reaching the project objectives was the non-homogeneous wall thickness of the part. This could cause long and inhomogeneous solidification resulting in feeding problems, ultimately leading to the risk of shrinkage defects. Because of that, the Döktaş engineering team designed five different ingate system options and compared them by using MAGMASOFT® autonomous engineering.