TECHNICAL PAPER PRESENTATION Saturday November 16 : Annex Hall F203~206
Session Chairperson
Ryobi Limited Hiroshi Matsuda

Session Chairperson
SHIBAURA MACHINE.CO., LTD. Yuto Hayashi

JD24-22

JD24-19Development of compression die-castingprocess using die clamping force

Integrated casting method using a dual-chamber
furnace with embedded pumping mechanism.

TOYO MACHINERY & METAL.CO.JP.,LTD ● Tomohiro Kitagawa,		 Aiki Hamada, Takashi Ijiri

Tounetsu Co., Ltd.
● Jyouji Yokoyama, Tsukasa Shimoto,		 Dr.Dassanayake Muditha

Die-cast products have so far dealt with blow hole countermeasuresand shrinkage porosity countermeasures separately for porosity
defects. It seems that there are many. This is because these two
types of porosity require a completely different approach to copingwith them.
This time, we have developed a new "super die casting method" asa new method that can deal with such a situation with one method.
Specifically, by casting by combining the PF die casting method
and the runner pressurization method, the amount of gas in theproduct can be reduced and the product density can be improved,
and we report this as a construction method that makes it
relatively easy to produce high-quality die-cast products.

In aluminum casting process, usually, molten aluminum istransported to the casting equipment by means of a ladle.
However, there are two main problems which are the maximum
amount that can be transported is below 100Kg and the amountis uncertain. In addition, the temperature of the molten aluminum
drops because of time consuming for transportation and weighing
process of molten aluminum to ensure high accuracy.
Molten aluminum pumping devices are used as an alternative toladles. But these devices are unstable in terms of the accuracy ofamount of pumping molten aluminum, and difficult to make themlarger to cater the need. In the other hand, if the molten aluminumis required to be dispensed with high accuracy, the maintenancecosts tend to be high. Furthermore, life span is shorter.
Therefore, to overcome all the above discussed problems, a new
pumping method using a dual-chamber furnace with embedded
pumping mechanism is introduced.

JD24-20

Characteristic investigation of burr
suppression and its countermeasures
SHIBAURA MACHINE CO., LTD.
● Shugo Mastuzawa, Satoru Aida,		 Yuto Hayashi, Koei Nakata

In recent years, with the increase in the size and the decrease inthickness of die casting products, injection has been increasing
in its speed. This enables short time filling, which is known that
improves product quality from the viewpoint of fine diffusionof molten metal and preventing lowering of molten metal
temperature. However, increase of injection speed increases
surge pressure hence necessary to consider burr blowing,
which not only inhibits safety but also deteriorates productquality.
Therefore, this study investigates and reports the mechanismof burr blowing and its countermeasures.
JD24-21Development of high cycle die castingmachine and casting technology
UBE MACHINERY CORPORATION, LTD ● Shunya Fujino, Yuki Miyamoto,		 Yuichiro Turugi,		 Naoki Ishibashi

With the rapid shift to EVs, die casting needs are changing to EV
parts, which cases for inverters, converters, E-axles, batteries,etc. and Giga-casting, that integrally molds chassis components.
In addition, new entrants from other industries are continuing toenter the market, leading to intensifying competition and falling
prices in the EV parts market. To survive the competition undersuch market conditions, it is important to generate continuous
profits in die casting production by reducing the unit price of theproduct. In actual casting using the 850t high cycle die castingmachine we developed, we achieved a high cycle time of 22.5s
in a four-sided slide mold that imitates a converter case. In thisreport, we will report on the means to achieve high cycles in themachine itself, auxiliary equipment, and casting process, as wellas the results of comparison with conventional machines.

JD24-23

Basic research to improve Mechanical
Properties of Aluminum Die Castings
NIHON KOHNETSU INDUSTRIAL CO., LTD.

● Ryo Isogai, Kiyoshi Okada,		 Kazuki Watanabe
MRDC Ltd.		 Dr. Mayuki Morinaka

Aluminum die casting has characteristics of its lightness andhigh productivity, therefore it can be adopted and expanded in thefield of especially automotive parts. Nowadays, considering theenvironmental considerations, the further adoption is considered.
ADC 12 die casting is nearly reaching to the upper limit. Highmechanical properties are demanded. i.e “Large size, Thin walland Complex shape”. Considering the aluminum parts with highmechanical properties, we adopt the casting method by use ofhighly ductile materials with expanded materials or virgin ingots,
however, it is not common.
Within a realm of luxury/sports cars ONLY.
If we adopt the die casting method by use of the secondary alloy
and the mechanical properties demand can be satisfied, the usage
application may be greatly expanded.
We researched on the mechanical properties depending on thecleanness of various molten alloys. Let us share our report and results.
Session Chairperson
NanoCast Masao Kikuchi

JD24-24

Proposal of next generation heat exchangesystem by Solid Phase Diffusion Bondingof ADC12 Die Castings
Suwa University of Science MOLE’S ACT Inc.
● Mirai Tsuchiya
MOLE’S ACT Inc.		 Toshiaki Kitazawa,		 Hiroshi Makibuchi

The main heat exchanger, the cooling fin, has a complex 3D
Japan Die Casting Congress 24

shape, high weight and volume, and low heat exchange directivity.
However, the thousands of semiconductors in EVs release a large
amount of heat, so a system with high heat exchange efficiency isessential. In addition, high productivity is required for automotiveparts, so production involving the processing of elongatedmaterials is not suitable from the standpoints of cost and time
efficiency. Therefore, a heat sink with a 3D cooling circuit wasdeveloped by solid-phase diffusion bonding of ADC12 die-castings,
which had been considered impossible. The heat exchange systemwith high yield and high thermal controllability can be constructedby using the diffusion bonding technique compared with theexternal heat dissipation type heat sinks with complicated fin
geometries. In this presentation, we report on the verification ofthis next-generation heat exchange system.
JD24-25

Development of die-casting technologythat can be joined to steel plates by spot
welding (SWAD)
Ahresty Corporation ● Atsushi Tateishi, Isao Akuzawa,		 Yoshiteru Kondo,		 Ph.D.(Eng.) Shunzo Aoyama, Nobuyuki Sakai

Environmental issues are increasing the need to reduce theweight of automobiles. In addition, the weight of the body is
being reduced by multi-material. Currently, die-casting is usedby joining to steel plates with SPR, but since spot welding cannot
be used at that time, it is necessary to assemble it on steel plateswith sub-lines, which requires additional investment and factory
space. Therefore, we developed a technology that can join steel
plates directly to die casting by spot welding. For spot welding,we considered inserting joint piece in die casting. By developinga joint piece, developing a process for inserting in a die casting,and investigating spot welding conditions with a steel plate, wewere able to develop a die casting technology that can be joinedby spot welding instead of SPR.
JD24-26

Innovation in the use of sensors for therealization of the smart factory
TOYOTA MOTOR CORPORATION● Tomohiro Koyama

In an era of once-in-a-century transformation, an era in which
there is no right answer, we are working on innovation toward
smart factories with the aim of transforming conventional
processes.
In the Ministry of Economy, Trade and Industry's Smart Factory
Roadmap, there are three levels of smartness: (1) data collection
and accumulation, (2) data-based analysis and prediction,and (3) data-based control and optimization. As one of themeans to achieve this, we believe that the method of collecting
measurement data is particularly important in the collection
and accumulation of data described in (1) above, because it
is not possible to correlate with measurement data that hasa low correlation with quality or defects even if it is analyzed.
Therefore, it is necessary to use a sensor with a high correlation
to the phenomenon. We will introduce an initiative that uses
sensors that can see the phenomenon we want to see.

25 Japan Die Casting Congress

Session Chairperson
AISIN Corp. Hideaki Kobayashi

JD24-27

Verification of Quality Improvement EffectMechanism of Partial Solid Die Casting by
Full Model Simulation Including Injection
PartsR&S Cast Solutions● Eitaro Koya
KYUSHU YANAGAWA SEIKI CO., LTD.		 Atsushi Kawauchi

The semi-solid die casting method is one of the methods toimprove the quality of die casting process. The issues of thesemi-solid die casting method are the cost increase due to theslurry manufacturing process and the difficulty in applying toADC12, an eutectic alloy with a narrow solidification range. The
Partial Solid Die Casting (PSDC) method has been proposed
to overcome these issues and to significantly reduce energy
consumption in the manufacturing stage. PSDC promotes
solidification nucleation by controlling the solid phase ratio in
the sleeve to around 0.05 by using casting conditions and molddesign and aims to improve the quality of thick-walled parts.
In this paper will verify whether it is possible to generate astable solid-liquid coexisting molten metal state in the sleeve by
numerical analysis using a full-model simulation including theladle feeding and injection mechanism.
JD24-28

Implementation of pressurized runnersqueeze pin system and PF methods fora void-less, high strength casting andtechnical initiatives for mass production
Kawasaki Industrial Co., Ltd. ● Kenichi Yamamura, Hiroya Kawasaki,		 Yuuta Shimizu, Takashi Sakai,		 Takayuki Hirano
Direct21 Corporation		 Norihiro Iwamoto, Osamu Nagasawa,		 Isao Kuboki, Shigeaki Saitou,		 Masao Kikuchi

The most frequently occurring defects in a die casting process
are porosities. It can be majorly classified into gas entrapment
and shrinkage porosity. These porosities have a huge impact
on the mechanical properties of the casted product and is oneof the significant reasons for the loss of its strength. The target
was to solve the problem of two different porosities that arecaused by different factors with one solution. The goal was
to integrate PF (Pore Free) die casting and pressurized runnersqueeze pins into the traditional high speed die casting process
to achieve excellent internal quality and mechanical strength andfurther achieve process stability during mass production. This
experiment was evaluated based on dedicated casting plans,
casting parameters, oxygen supply conditions and pressurizedrunner squeeze pin parameters. The results, effects and future
prospects are discussed in this technical paper.

JD24-29

Development of Manufacturing andMaterial Technologies for High-Impact
Resistance Aluminum Die-Casting
ProductsRyobi Limited ● Mamoru Murakami, Shigetake Kami,		 Ph.D.Akihito Hasuno, Yusuke Yoshida, Keisei Inoue

In recent years, the shift from iron to aluminum for material
substitution has gained renewed attention due to demands for
reducing environmental impacts and controlling vehicle weightamid the transition from internal combustion engines to electricvehicles. This development aims to extend the application rangeof die casting to structural members, focusing on manufacturingand material technology advancements to enhance ductility
and impact resistance. Although it is well-known that T7 heat
treatment enhances the ductility and impact resistance of diecast materials, challenges such as high costs and increased
CO2 emissions remain. This paper explores not only material
development but also cost-effective and lower CO2 emission
heat treatment technologies and non-heat-treated solutions
as alternatives to T7. By incorporating various innovations indesign, testing, evaluation, and manufacturing techniques, wehave realized the die casting of products with superior impact
resistance. This report outlines the overview of our findings.

ホテル宿泊のご案内 HOTEL RESERVATIONS
宿泊をご検討の方は、下記の各予約サイトよりご予約ください。

日本語サイト / 近畿日本ツーリスト
https://www.knt.co.jp/?tc=3349B

英語サイト（海外の方）

KINTETSU INTERNATIONAL（JTO/Japan Traveler Online）

https://www.japantraveleronline.com/af/9404Q/hotellist/G1180502/

繁体字サイト ( 海外の方 )KINTETSU INTERNATIONAL（JTO/Japan Traveler Online）

https://www.japantraveleronline.cn/af/9404Q/?_ga=2.86079128

Japan Die Casting Congress 26