HyDrun

Analysis of the interface during inline hybridization of metal die-casting
and injection moulding

In the development of complex and highly resilient lightweight structures, there is a trend towards using different materials in one component. Different manufacturing processes are often combined to produce such multi-material or hybrid components. Among other things, this can reduce high investments in the purchase of machinery or save storage and transport costs. In particular, the innovative combination of light metal die casting and plastic injection moulding is being intensively investigated at ILK under the name of hybrid casting on a new type of DuoCast vertical die casting machine (Fig. 1) with integrated bolt-on injection moulding. With the help of a robot change system for component handling, further process steps such as deburring and functionalisation of the surface areas for the injection of the plastic are carried out in the synchronous production of complex hybrid structures on one system. Thanks to the high degree of automation, cycle times, energy consumption and costs can be reduced. Following the successful hot commissioning of the hybrid casting system, process parameter studies were carried out in the HyDrun project to optimise casting quality and component handling. The current focus is on the integration of a laser unit for surface structuring and functionalisation. In addition, a sub-goal of the project is to develop a recycling concept for the structures produced using the hybrid casting process.

View of a machine. — Fig. 01: View of the die-casting cell with the ‘DuoCast’ vertical die-casting system and peripheral machines.

Period

01.06.2021 – 31.05.2024

Project partners

Consortium Leadership

Druckguss Service Deutschland GmbH

Project partners

Associated partner

GK Concept GmbH

Funding

Federal Ministry of Education and Research (BMBF): Funding line HyMat2 – "Hybrid materials – New Possibilities, New Market Potentials" (HyMat)
Funding code: 03XP0383I