Abstraktes Bild mit leuchtenden blauen und orangefarbenen Lichtspuren und Punkten auf einem dunkelblauen Hintergrund, das an Geschwindigkeit, Technologie oder Datenfluss erinnert.

Technologies

Casting technology is the shortest path from liquid metal to the finished product. We take advantage of this and optimally unite manufacturing processes. We apply consistently efficient manufacturing technologies and support them by cutting-edge IT technologies. This way we avoid buffer stocks. That means tight closed control loops that improve process quality.

We produce sophisticated products, made of aluminum and magnesium alloys, by using most modern, state-of-the-art casting and machining technologies. Integrated, certified quality control loops ensure process stability and specification capability. We produce components which are used throughout the automotive industry.

High Pressure Die Casting

Große Industriemaschine mit zwei kreisförmigen Mechanismen und verschiedenen Rohren und Metallstrukturen in einer hell erleuchteten Fabrik oder Produktionsstätte.

In the die-casting process molten metal is forced at high speed and under high pressure into molds made of tool steel. The filling time of the mold counts less than 6-25 milliseconds and the pressure is up to 1000 bar. This process is characterized by its high productivity and dimensional stability.

We manufacture in this process, complex products such as transmission housings and internal transmission components, steering housings and engine components.

We produce die-cast components that are weldable and suitable for a two-stage heat treatment (T6, T7). The KSM Castings Group developed a special vacuum-pressure casting process, the Controlled Vacuum Casting (CVC^®).

Ein 3D-gerendertes Bild einer blauen industriellen Spritzgießmaschine mit getrennten Werkzeughälften, die die inneren Komponenten und Maschinendetails offenbaren.

High Pressure Die Casting Process Animation

Controlled Vacuum Casting (CVC^®)

Nahaufnahme einer Spritzgießmaschine, die blaue Kunststoffteile in einer Metallform formt, mit einer mechanischen und industriellen Umgebung im Hintergrund.

In Controlled Vacuum Casting (CVC^®), both the mold and casting chamber are evacuated during mold filling. Several independently controlled vacuum circuits allow a very rapid evacuation procedure and an extremely high negative pressure in the cavity. A specially developed casting plunger prevents leakage between casting and casting plunger.

We use CVC^® in the chassis and body area. In CVC^®, manufactured components have excellent properties in terms of strength and ductility and are suitable for welding and punching rivets.

Zwei blaue Spritzgussform-Werkzeughälften sind getrennt dargestellt, wodurch der innere Formhohlraum mit metallischen Komponenten sichtbar wird. Die Form wird in der Fertigung zum Formen von Teilen durch Einspritzen von Material verwendet.

CVC^® Process Animation

Gravity Die Casting

Eine Nahaufnahme von Industriemaschinen mit Kabeln und Metallteilen, hauptsächlich in Blau- und Weißtönen, die eine komplexe Fertigungsanlage aus der Überkopfperspektive zeigen.

Using the technology of gravity die casting or permanent mold casting, the melt is poured under the influence of gravity through a gating system into the mold. The shrinkage porosity is absorbed by the feeder and overflow system, and the solidification is directed through cooling the mold. Due to the low porosities, we achieve high mechanical properties over a heat treatment.

In gravity die casting, we manufacture a wide variety of complex components with wall thicknesses down to 4 mm and with hollow profiles. The method is suitable for the production of safety components for chassis applications, such as single, or multi-piece sub-frame constructions.

Ein 3D-gerendertes Bild einer komplexen industriellen Form oder eines Werkzeugs, hauptsächlich blau und grau, mit mehreren miteinander verbundenen Komponenten und Metallplatten.

Gravity Die Casting Process Animation

Multi Tilt Casting (MTC^®)

Eine moderne Fabrikhalle mit automatisierten Maschinen und Robotern, darunter ein auffälliger blauer Roboterarm, umgeben von Sicherheitsbarrieren und Industrieanlagen in einer sauberen, gut beleuchteten Umgebung.

In the tilt casting process, Multi Tilt Casting (MTC^®), the mold is tilted to the git side at the beginning of the filling. By the subsequent tilting the melt fills the mold. This method provides a lower air lock and allows precise control of the filling speed exactly.

As in gravity die casting, we can fill the mold and direct the process of solidification of the material by cooling.

The KSM Casting Group manufactures both small, compact components, and very large components in the tilt-mold casting process.

Counter Pressure Casting (CPC)

Eine Nahaufnahme einer Industriemaschine mit einer großen zylindrischen Metallkammer mit vier segmentierten, strukturierten Oberflächen im Inneren, umgeben von Kabeln, Rohren und Schalttafeln.

Counter Pressure Casting (CPC) is a further development of conventional low-pressure permanent mold casting. By this newly developed method, the filling of the mold and the solidification of the material can be realized under pressure because the pressures are independently adjustable in the furnace and the mold. In conjunction with a high cooling rate, we achieve excellent mechanical characteristics.

The KSM Castings Group is the world's largest manufacturer of suspension parts in the Counter Pressure Casting Process (CPC). We manufacture Counter Pressure Casting components that are exposed to very high static and dynamic loads.

Nahaufnahme einer Industriemaschine mit Metallteilen und Drähten, die in Bewegung mit einer blauen Unschärfe aufgenommen wurde; in der rechten unteren Ecke ist ein weißes Symbol für eine Wiedergabetaste zu sehen.

CPC Prozess

Eine Nahaufnahme einer mechanischen Baugruppe mit Metallkomponenten und blauen, kreisförmigen Plattformen, bei der die Teile getrennt sind, um die innere Struktur zu zeigen. In der unteren rechten Ecke erscheint ein kleines Abspielsymbol.

CPC Prozessanimation

Machining

Ein großer blauer Industrieroboterarm arbeitet in einer hellen, modernen und hochautomatisierten Fabrikumgebung, umgeben von komplexen Maschinen, Kabeln und fortschrittlichen Fertigungsanlagen.

Everything from a single source, including precision machining of the casting is done on site. The sophisticated nature and challenges of the components we produce require an overall production approach to ensure consistent quality of the product. The precise coordination between the foundry and machining process is necessary to guarantee dimensional accuracy and quality.

Critical casting requirements of the component geometry are maintained and tuned within our internal tooling shop. The dimensional control and quality of the component is integrated into our overall machining process approach from work-holding to machine tools. We utilize extensive in-line gauging and off-line coordinate measuring machines to check and verify all dimensional aspects of the finished component.

The KSM Castings Group ensures the critical coordination between casting- and machining requirements. Over 80% of all components are machined directly on site.

We consider the entire process from the begining, thus ensuring the quality of your product.