Boozer: die casting machines

Solutions for new body-in-white concepts and structural applications

Bühler is expanding with the launch of the Carat 560 and Carat 610, and the recently announced Carat 840 to meet market trends. "Structural components have clearly gained importance in the automotive industry in recent years, with a trend towards even larger parts. This represents a clear opportunity for the die casting industry," says Cornel Mendler, Managing Director Die Casting.
Larger, more complex parts produced by the die casting process are a current trend. The automotive market is seeing discussion of new body-in-white concepts, with a trend toward larger and larger parts produced in aluminum die casting. This offers the ability to functionally integrate other parts, producing them in a single step instead of several production steps. This, in turn, reduces complexity and increases productivity in the body-in-white automotive manufacturing process. "We see enormous potential for an even more efficient production process for the automotive industry; it's a fascinating opportunity for die casting," explains Cornel Mendler, Managing Director Die Casting.
The new Carat 560 and Carat 610 with closing forces of up to 61,000 kilonewtons (kN) are the latest addition to Bühler's portfolio. In November 2020, Bühler announced the Carat 840 - with a closing force of 84,000 kN. "The Carat platform has been on the market since 2007 and has always been the solution for large die-cast parts. In 2020, we have seen a huge increase in demand for ever larger machines, up to twice the size of before. Therefore, we are very proud to have been able to announce the Carat 840," says Martin Lagler, Global Director Product Management & Marketing at Bühler Die Casting. - "Imagine a die casting machine as big as a house, 6 meters high and on an area of more than 60 square meters. It's not just the size that's impressive, but also the performance." The Carat 610 can melt more than 100 kg of liquid aluminum in a mold in a matter of milliseconds, holding the mold firmly in place with a force of 61,000 kN. 
The application of the Carat die casting platform has always been for parts with complex geometries such as structural parts. Today, these parts are getting larger and there are other applications as well. These include battery housings for electric vehicles and new body-in-white concepts. "With the rise of electric mobility, automotive production is being rethought in many ways, for example down to how the basic structure of the car is produced. This opens up new opportunities for the die casting industry," says Cornel Mendler.
Carat's two-plate die casting solution with minimal deformation and a high degree of dimensional accuracy has long proven its value for the production of large and complex structural components. Equipped with Bühler's unique grit control system for real-time closed-loop control, the Carat enables high-quality parts to be cast, repeatedly.
All machines in Carat's expanded portfolio, are equipped with Bühler's DataView control unit - which makes controlling the die casting machine easier and more intuitive with its multitouch screen, making programming up to 25 percent faster. In addition, each machine features Bühler's new energy frame concept with a clear and distinctive arrangement of energy couplings. The Carat series also offers the option of servo drive technology.
Bühler not only provides die casting machines for the automotive industry, but also other innovative solutions. To help meet the growing demand for batteries, Bühler offers new technologies for the efficient production of active electrode materials and electrode slurries. Solutions include equipment for wet grinding of active materials and precursors, as well as continuous twin-screw electrode slurry mixers.

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