Hts brosura final_press

OPTIMIZE YOUR CASTING PROCESS – INCREASE QUALITY AND PROFITABILITY

Thermal management and advanced manufacturing for productivity improvement in

mass production industry.

ACTIVITIES

MANUFACTURING BRANDS

R&D FACILITIES• metallurgical laboratory• mechanical testing laboratory• dimensional control laboratory• Material Process Modeling (Abaqus, Procast)

ENGINEERING• CAD and CAM• computational optimization

MACHINING • turning, grinding, milling• wire and sink erosion

HEAT TREATMENT• vacuum heat treatment• conventional hardening, tempering, annealing• sub-zero and cryogenic treatment

SURFACE ENHANCEMENT TREATMENT• series of NITOP / OX and PLAZNIT / OX

processes• series of carburizing and carbonitriding

processes

WELDING SERVICES• surface enhancement technologies• refurbishment and maintenance

Innovative industrial components, thermal management systems, and technology services developed for advancement of mass-production industry.

Heat treatment services of highest quality and

reliability.

Extrusion tooling and services tailored for our customers

requirements.

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INDUSTRIAL COMPONENTS, BUILT TO PERFORM Our products combine innovative design with selection of best materials. They are designed by our experienced engineers with assistance of Materials and Process Modeling Division, using state-of-the-art Computational Modeling Systems, and are fabricated using Advanced Manufacturing Technologies.

RESEARCH AND DEVELOPMENTIt is our strategic decision to dedicate resources to Research and Development in order to provide our customers with advanced and innovative solutions, assuring sustainable competitive advantage.

Materials and Process Modeling Division, the hearth of R&D, is developer of innovative tooling products and novel Thermal Management technology.

OUR COMMITMENT

OUR FACILITIES

We are committed to development and innovation of industrial components utilized in extreme thermal conditions, to achieve optimum performance and prolonged in-service life at maximum efficiency and cost effectiveness.

EFFICIENT PRODUCTIONState-of-the-art technologies are utilized for production of our components. In house Premium heat treatment and surface treatment facility, STEEL, highly innovative iMFT™ technology, as well as machining and advanced weld-surfacing facility guarantee most efficient production.

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iMFT™REVOLUTIONARY TECHNOLOGY With highly innovative iMFT™ technology we are setting new boundaries in manufacturing of conformal cooling components for die-casting industry.

Absolutely the largest high-performance conformal-cooling industrial component ever built

ADVANTAGES

Component dimension• 900 x 600 x 500 mm

Functionality• mirror polished inner

channels• no geometry limitations

Material used• premium forged tool steel

as required by the process

Efficiency• short lead time• high cost efficiency

First industrial component with arbitrary shape-mirror polished internal arrangement

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iTherm™ DIE CASTING SET OPTIMIZE YOUR CASTING PROCESSiTherm™ casting set is an ultimate solution to optimize your casting process by reducing the casting cycle time.

Highly-innovative products are designed to provide best solution for reduction of casting cycle time and improved in-service life. Proven-performer products, delivering an ultimate solution in heat transfer and durability, are used where optimum process solutions are needed.

THE ULTIMATE SOLUTION TO INCREASE YOUR PRODUCTION EFFICIENCY

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ADVANTAGES

• increased productivity due to significant reduction of cycle time

• increased productivity due to less or no defects during production series

• increased lifetime of components

• reduced quantity of scrap• significantly decreased

circumferential and axial deformation of the shot sleeve – important for diameters 80+ mm

• lower production and maintenance costs

STEP 1Provide us information on the current process or technical requirements of your new project.

STEP 2Collaborate with us to develop iTherm™ CASTING SET for your process.

STEP 3Our engineers will optimize your casting set by performing computer simulation of your casting process.

STEP 4We will fabricate the unique, high performance iTherm™ CASTING SET for you.

STEP 5We will implement the solution to your process and monitor its performance.

To develop and deliver die casting set that will maximize your production results we propose a 5 step collaboration process:

Conventional casting set iTherm™ casting set

iTherm™ DIE CASTING SET OPTIMIZE YOUR CASTING PROCESS

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Conventional casting set iTherm™ casting set

iTherm™ casting set is an ultimate solution to optimize your casting process by reducing the casting cycle time.

iTherm™ DIE CASTING SET OPTIMIZE YOUR CASTING PROCESS

iTherm™ casting set - reduced biscuit solidification time by up to 30%.

Temperature distribution at the end of cycle.

650

550

450

350

250500 100 150

Time (s)

Tem

pera

ture

(ºC)

200 250 300 350 400 450 500

conventional iTherm™

Cycle time - conventional: 83 sCycle time iTherm™: 58 s

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ADVANTAGES

iThermTM system provides highest cooling efficiency of the piston front and side surface with:

• improvement of cast part quality

• reduction of casting cycle time

iTherm™ CASTING PISTONA single body piston with an innovative Internal Cooling System iThermTM.

DESIGN TYPE DESCRIPTION ADVANTAGEiTherm™ Single body piston made of premium forged hot-work

steel with Internal Cooling System and sealing ring.Changing of the sealing ring directly on the machine without disassembling the piston. Improvement of cost efficiency.

TECHNICAL CHARACTERISTICS

iThermTMSteel Copper

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iTherm™ CASTING PISTON

* We can perform a computer simulation of your casting process to determine an iTherm™ piston design for optimum cooling efficiency and cycle time. Based on customer’s casting process data. ** Figure shows temperature at the centerline underneath the piston front surface, T, normalized by temperature of molten metal, Tmm, presented as a function of time, t, throughout one casting cycle, tc.

iThermTMSteel Copper

Temperature field in different pistons computed using the same process parameters.

250 °C

50 °C

Temperature is higher in pour phase compared to standard Cu piston (effect on cast part quality)

Extreme temperature drop compared to standard Cu piston (effect on cycle time)

0,7

0,6

0,5

0,4

0,3

0,2

0,1

0,00,20,0 0,4 0,6

t/tc

T/T

mm

**

0,8 1,0

standard Cu piston standard steel piston iTherm™ piston

1. EFFECT ON QUALITY OF CAST PARTIn pour segment, the piston temperature is higher.

2. EFFECT ON CYCLE TIMEExtreme temperature drop occurs in pressurization segment.

3. LONG LIFE TIME OF THE PISTONResults show high durability of the iTherm™ piston.

iThermTM single body piston in-service life is extended by reduction of transient stresses in the piston front that inhibit cracking.

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iTherm™ DISTRIBUTOREXTREME PERFORMANCE AND DURABILITY

iTherm™ distributor is specially designed to provide an excellent solution for reduction of casting cycle time and improved in-service life, thanks to the Innovative iTherm™ technology.

DESIGN TYPE DESCRIPTION ADVANTAGEiTherm™ Single body distributor made of premium forged hot-

work steel, engineered for highest series production thanks to the innovative Internal Cooling System.

Optimized cooling system. Reduction of casting cycle time. Prolonged in-service life.


ADVANTAGES

iTherm™ system provides improved cooling efficiency and prolonged in-service life.

Conventional distributor iTherm™ distributor

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iTherm™ DISTRIBUTOREXTREME PERFORMANCE AND DURABILITY

A single body distributor with an innovative Internal Cooling System iTherm™. It presents an excellent solution for reduction of casting cycle time and improved in-service life.

Conventional distributor iTherm™ distributor

Temperature field comparison just before lubrication in conventional and iTherm™ distributor. Note temperature difference of 210 °C.

325 °C

25 °C

Shot SleeveFilling

PistonMoving

Max pressure 1000 bars-solidification

Time saving

Part ejection, tool lubrication ...

Tem

pera

ture

Time

Surface temperature comparison.


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SHOT SLEEVESDURABILITY AND RELIABILITY OF OUR SLEEVES INCREASES YOUR CASTING EFFICIENCY

STEP 1Shot sleeves are made exclusively using tool-steel produced by premium European steel manufacturers.

STEP 2Every sleeve is designed according to specific customer needs. We provide technical drawing of the sleeve for your confirmation before fabrication.

STEP 3Rough and fine machining is made by our experts using state-of-the-art equipment.

STEP 4Heat treatment and surface enhancement treatment are the expertise of HTS IC Group.

STEP 5To grant 100% quality assurance all sleeves pass HTS IC Quality Control process before shipment to our clients.

We manufacture all our shot sleeves in the integrated process:

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SHOT SLEEVESDURABILITY AND RELIABILITY OF OUR SLEEVES INCREASES YOUR CASTING EFFICIENCYOur Engineers will always help you choose the right sleeve according to your specific casting process. In order to meet your expectations HTS IC developed several different shot sleeve types.

DESIGN TYPE DESCRIPTION RECOMMENDED APPLICATIONSTANDARD • premium hot-work steel in combination with NITOP

nitrided surface provides high resistance to high temperatures, erosion, and washing phenomena

• cooling ring and cooling channels can be included

• lower production series and economy production

OPTIMUM • specially developed working-surface layer on premium quality hot-work steel

• Improved resistance to high temperatures, erosion, and washing phenomena

• cooling ring and cooling channels can be included

• applicable to moderate production series with improved performance compared to STANDARD quality sleeves

PREMIUM • highest quality tool steel and specially developed heat-treatment and surface-treatment processes

• highly resistant to both gross cracking and thermal-fatigue cracking caused by cyclic thermal loading during operation

• cooling of the pour zone is recommended. Cooling channels are included in PREMIUM shot sleeve

• extreme exposure to thermal fatigue loading• high volume production requires PREMIUM line shot

sleeves to reduce costs of production downtime and maintenance - reduced costs of production downtime and maintenance, thus assuring good price to performance ratio

MULTIX MULTIX with Passive Thermal Regulation system improves temperature homogeneity over the sleeve circumference. Main benefits are:• significant reduction of axial sleeve bending• prevented excessive ovalization of the bore hole• reduced temperatures in the surface beneath the

pour zone, thus improving resistance to erosion and washing failure

• extreme exposure to thermal fatigue loading• long shot sleeves in high volume production. lt

also assures prolonged in-service life of casting pistons - reduces costs of production downtime and maintenance, thus assuring good price to performance ratio

WX • WX shot sleeve is developed to solve particular failure mechanisms resulting from extreme operating conditions

• WX is fabricated as an individual application in collaboration with customer

• WX is fabricated using highest quality surfacing alloys and advanced weld surfacing

• technology to provide best possible in-service life and production

• performance of each individual customer’s application


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iTherm™ CASTING COMPONENTSTHERMALLY OPTIMIZED FOR HIGHEST PRODUCTION EFFICIENCY AND PRODUCT QUALITY

Highly-innovative products are designed to provide best solution for reduction of casting cycle time and improved in-service life. Proven-performer products, delivering an ultimate solution in heat transfer and durability, are used where optimum process solutions are needed.

To develop and deliver the part that will maximize your production efficiency we propose a 5 step collaboration process:

STEP 1Provide us information on the current process or technical requirements of your new project.

STEP 2Collaborate with us to develop the optimized thermal management solution for your process.

STEP 3Our engineers will optimize the solution by performing computer simulation of your casting process.

STEP 4We will fabricate the unique, high performance iTherm™ component for you.

STEP 5We will implement the solution to your process and monitor its performance.

Conventional component iTherm™ component

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iTherm™ CASTING COMPONENTSTHERMALLY OPTIMIZED FOR HIGHEST PRODUCTION EFFICIENCY AND PRODUCT QUALITY

iTherm™ component increased productivity by more than 20%.


Conventional component iTherm™ component

Temperature field comparison just before lubrication in conventional and iTherm™ component. Note temperature difference of 210 °C.

25 °C

325 °C

By implementing iTherm™ we achieved:

• significant increase of the casting product Quality

• reduced scrap and casting product non-conformity

• increased productivity

400

300

200

100

00 50 100 150 200 250 300

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SLOVENIA

HTS IC d.o.o.Litostrojska cesta 60SI-1000 Ljubljana

MANAGMENT

Robert VugaManaging Director, CEOT +386 1 5000 110F +386 1 5000 [email protected]

SALES

Matej GrumT +386 1 5000 114F +386 1 5000 [email protected]

TECHNICAL

Aleš BriliT +386 1 5000 113F +386 1 5000 [email protected]

AUSTRIA

HTS IC GmbHWienerbergstraße 11/12AA-1100 [email protected]

Mr. Patrick EsterleT +43 664 466 [email protected]

CZECH REPUBLIC

Kovinotrade Praha Spol s.r.oHolečka 39Praha 5150 00 Praha

T +420 725 927 [email protected]

GERMANY

HTS IC GmbHWienerbergstraße 11/12AA-1100 Wien

SOUTHERN GERMANY


NORTHERN GERMANY

Kieran GriffinT +49 151 1249 [email protected]

UK & IRELAND

Kieran GriffinT +44 740 885 [email protected]

ITALY

HTS IC Italia Mr. Fedele CasseseT +39 3666 624 [email protected]

Omnia Tecno S.r.l.Via Agnelli 19 21013 Gallarate (VA)T +39 0331 795 [email protected]

SPAIN

Alrotec technologies slAvgda. Les Puntes Nau 5 (Cantonada C/Dinamarca)43120- Constanti (Tarragona)

T +34 977 52 55 61F +34 977 52 55 [email protected]

SWEDEN

Procast Rebecca Ammer ABGullanabba 107314 91 Hyltebruk

T +46 (0)371 [email protected]

OTHER COUTRIES

HTS IC GmbHWienerbergstraße 11/12AA-1100 Wien


CONTACT US

Hts brosura final_press

Automotive

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