Die-casting: replacing steel with aluminum

Aluminum die-cast products are lightweight, environmentally-friendly and easy to recycle. Our die-cast technology produces high-strength, high-density, high-precision components, which can replace parts that were previously produced from steel. Thin-wall and processless die-casting further reduces weight and cost.

Semi-Hot Chamber System

Pressure-Resistant High-Strength Aluminum Die-casting

The semi-hot chamber system pours the molten metal into the die while preventing the metal from coming into contact with air. Another feature is the fact that the use of slow-speed filling and vertical injection minimizes the amount of air during filling, which forms excellent high-density parts with few blowholes. This enables heat treatment and allows the parts that were conventionally produced out of other metals to be replaced with aluminum, which reduces weight.

55%
Weight reduced
30%
Cost reduced

High Strength (Treated with T6 Heat Processing)

Pneumatic Components

Hydraulic Components

High-pressure Fuel Injector Components

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Center Gate System

High-Circularity Aluminum Die-Casting

A system known as the center gate system is used to pour the molten metal uniformly in a radial pattern from the center of the part when manufacturing circular parts. This results in well-balanced filling to improve dimensional precision, and it achieves a roundness level of 0.08 with machine pressing. It also reduces the number of blowholes, and extends the life expectancy of dies. The center gate system and a high-strength silicon alloy is also used to succeed in creating aluminum die-cast hub brakes, drum direct clutches and other such parts with high levels of circularity that need to be wear-resistant and that have been molded on steel presses up until now.

50%
Weight reduced
5-20%
Cost reduced

Piston for CVT in passenger car

Hub Brake

Drum Direct Clutch

Piston for AT in passenger car

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THIN-WALL/PROCESSLESS DIE-CASTING METHOD

KSK’s Cutting-Edge Technology for Producing Lighter Parts

As demand increases for EV, PHV and other such vehicles, there is now a tremendous clamour in the automotive industry to create vehicles which are even lighter. Achieving thinner casting is an extremely important step for reducing the weight of aluminum-cast parts, and KSK has successfully developed a wall with an incredible thickness of just 0.6mm. We are currently producing thin-cast prototypes for mass-production, and are successfully promoting these lightweight parts to our customers. This development goes hand-in-hand with our ‘processless’ production. Not only does it reduce cost, it is also desirable from an environmental perspective.

Conventional Components

Developed Components

Conventional Components

Developed Components

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