Aluminum cast pistons | Compatible with difficult-to-cast material AC8B, with a track record of expansion into other industries.
For materials with peculiar casting properties such as AC8B, please consult us. We will extend our achievements in piston manufacturing for compressors to components in other industries and provide consistent support up to mass production.
Have you ever received inquiries about materials with casting characteristics that are difficult, such as AC8B, which has challenges with flow and shrinkage? For parts like pistons, where dimensional accuracy and strength must be balanced, the properties of the material increase the difficulty of casting. AC8B-based alloys containing Si, Ni, and Cu have a low thermal expansion coefficient and excellent high-temperature strength, but they also have low fluidity and significant shrinkage during solidification, leading many manufacturers to postpone mass production. Karmo Casting designs and manufactures wooden and metal molds in-house and possesses five casting processes: sand casting, self-hardening, alkaline phenolic, cold box, and metal mold casting. We propose mass production designs that minimize yield loss, even for materials with challenging characteristics, by confirming solidification and flow in advance through casting simulations. This product is an example of how the casting and machining technology for AC8B pistons developed for compressor parts has been applied to sliding parts and heat-resistant components in other industries, such as automotive and industrial machinery. We offer a technical document summarizing the break-even points by method and considerations for handling difficult-to-cast materials, available for free. Please download it from the link below.
basic information
【Supported Lot】From 1 piece 【Casting Size】50mm square to 1,000mm square / Minimum thickness 2mm (local)・3mm (overall) 【Product Size】φ150mm × Height 60mm (based on compressor piston) 【Supported Materials】 - Aluminum Alloys: AC2A / AC2B / AC3A / AC4A / AC4B / AC4C / AC4CH / AC4D / AC7A / AC8B (10 types) - Copper Alloys: CAC403 / 406 / 502 / 301 / 302 / 303 / 702 / 703 (8 types) - Heat Treatment: T6 and others (AC8B is suitable for applications requiring low thermal expansion and high-temperature strength) 【Casting Processes】In-house capabilities for 5 methods: sand mold / self-hardening / alkaline phenol / cold box / die 【Machining】15 units of 5-axis machining centers, 2 gantry-type MCs, 3 vertical MCs, 2 NC lathes / numerous achievements with geometric tolerances of ±0.03 【Inspection】2 contact-type 3D measuring machines, 1 non-contact 3D digitizer (deviation 50-80μ) 【Surface Treatment】Arrangements for plating, painting, anodizing, and impregnation (compliant with RoHS and REACH) 【Certifications】ISO9001 (2012) / JIS Q 9100 (2015) / KEMS Step 2
Price information
If you provide us with drawings or physical samples, we will offer a free estimate. For materials with casting characteristics like AC8B, we will conduct pre-verification through casting simulation and propose conditions that minimize yield loss. By applying the manufacturing methods developed for compressor pistons to components in other industries, we may be able to reduce costs. Please consult us first regarding the shape and material.
Price range
P2
Delivery Time
OTHER
Due to the difficulty in casting materials, the initial process will take at least 3 weeks, including casting simulation. After transitioning to mass production, it can be shortened by reviewing the method. Please feel free to consult with us.
Model number/Brand name
AC8B-T6
Applications/Examples of results
【Industries Served】Automotive・CASE / Railways / Aerospace / Marine / Semiconductors・Communication Equipment / Robotics / Machine Tools / Agricultural Machinery / Power・Energy 【Delivery Achievements】 ■ Pistons for compressors (AC8B-T6 / Applications requiring low thermal expansion and high-temperature strength / From 1 piece) ■ Sliding parts for automotive EVs (AC8B-T6 / Repurposing casting technology for compressors) ■ Heat-resistant parts for industrial machinery (AC8B / Confirmed dimensional stability in high-temperature environments) ■ Cylinder cases for railway vehicles (AC4CH-T6 / Complex shape with 6 cores / Delivery time of 2 weeks) ■ Aluminum parts for ships (AC2A-T6 / Small size, high precision, and large quantities) ■ Bases and pedestals for semiconductor manufacturing equipment (AC4CH) 【Used in Such Situations】 - Unable to find a supplier for materials with casting peculiarities like AC8B - Want to repurpose the same material and method for industries other than compressors - Need only a few pieces for prototype evaluation - Replication of parts that only exist in physical form without drawings 【Achievement Scale】Over 500 prototype and development achievements annually. 5,000 items from 200 companies in the last 5 years.
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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.