Industrial machine parts, aluminum castings, complex shape with 11 cores AC4CH-T6.
Hollow nests, pressure leaks, pinholes, inclusions. Solving casting defects that other companies could not stop through two casting processes and CAE analysis.
The defect rate of castings requested from other companies is not decreasing. The defects in mass-produced items are not stopping. Even when we request countermeasures, we receive the response, 'It's difficult because it's casting'—this is the most common consultation received from the procurement and quality assurance departments. Casting defects cannot be resolved without identifying the causes in the casting plan, sand, melting conditions, mold coating, and temperature. Factories that only have a single casting process cannot perform this differentiation. Our company has five casting processes in-house: sand mold, self-hardening, alkaline phenolic, cold box, and metal molds. Based on numerous casting simulation results, we predict the location of defects at the design stage. Since both wooden and metal molds are produced in-house, we can handle everything from plan changes to remanufacturing internally. [Results Achieved] Over 100 problem-solving cases / 100 companies and 500 items in the last 5 years ■ Major machinery manufacturer: defect rate over 80% → less than 5% ■ Marine valve case: shrinkage defect 70% → about 5% ■ Resolved pouring defects in communication equipment frames, pinholes in industrial machinery frames, and inclusions and casting surface defects in generator control cases. We are offering a free copy of the 'Aluminum Casting Defect Countermeasure Guidebook,' which summarizes countermeasures by cause.
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Die-cast aluminum alloy
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Parts for industrial machinery Size: 450×250×150
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At Karmo Casting Co., Ltd., we engage in aluminum processing, aluminum casting, and the casting of copper alloys other than aluminum. Manufacturing has continuously supported the backbone of Japanese industry. At Karmo Casting, we have maintained that spirit and pride, dedicating ourselves to pioneering initiatives in the industry since our founding. Our primary goal is to build partnerships with our customers. To achieve this, we believe it is essential to flexibly adapt to changes in the times and realize all kinds of needs. Our relentless pursuit of technical expertise, responsiveness, quality, and speed reflects this attitude. While sensitively and swiftly understanding our customers' thoughts, Karmo Casting will continue to accumulate tireless efforts and changes as a manufacturing company that is chosen and needed by our customers.