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Metal Casting Technologies : March 2008
The aim of this project was for Rogers Industries to be able to minimise quality problems and to move to an alternative, low pressure die casting (LPDC) manufacturing process. This would enable Rogers to supply Bocar with high quality cast components for subsequent post casting manufacturing at Bocar and eventual supply to the automotive companies. As a result of the project, Rogers Industries Pty Ltd was able to implement the LPDC process and improve their quality control capabilities, ultimately improving product quality. A process development team was formed from key manufacturing staff from Rogers and Bocar along with CAST researchers. The team reviewed current operations at the aluminium foundry section of Rogers Industries, the molten metal processing facilities and procedures in particular, and made recommendations to both Rogers and Bocar on what production practice Trust your most complex cores to INCAST ®. The ideal combination of geometry, density and particle size distribution, INCAST improves critical core making and casting properties including binder utilization, permeability and dimensional stability. Higher strength cores, better surface finish and increased efficiency and yield are the INCAST advantages. These sands are engineered for the metalcaster. Optimize Core Performance Unimin Australia Limited Tel.: +613 9586 5400 Fax: +613 9586 5411 E-mail: firstname.lastname@example.org Worldwide: www.metalcaster.com CORE AND MOULDING SANDS ® ® INCAST is a registered trademark. All rights reserved. ©2003 A new bumper bar component to be supplied to Bocar was selected as the focus product for the manufacturing process development work undertaken by Rogers Industries. As part of a CAST CRC Best Practice program, this project has facilitated production of a new automotive product range for Rogers and has established it as a supplier of high quality components. This image is of the integrated aluminium alloy Nissan Pathfinder bumper system developed by Bocar, with cast components supplied by Rogers Industries.