NEW TECHNOLOGIES FOR NEW CHALLENGES

MAGNESIUM INJECTION MOLDING


INJECTION MOLDING

is an injection molding process where the magnesium alloy is advanced by means of a feed screw into the mold. It differs from die casting in that a hot-runner can be used in the mold to reduce cycle time, material usage and flow paths and to improve the quality and properties of the component. At LTC-GmbH we currently employ one HyMet 1000t (1000 tons clamping force), two HyMET 650t (650 tons clamping force) and two HyMet 500t (500 tons clamping force) Injection Molding systems from Husky Injection Molding Systems Ltd.


The application of Injection Molding is limited by machine sizes, especially by the size of the feed screw in which the granule is plasticized. The single-stage, closed injection Molding process, during which the desired magnesium alloy is injected into the mold at a rate of up to 6,000 mm/s, minimizes the entrainment of gases and oxides, and improves the component’s mechanical properties. The material used is heat treatable and weldable.


Unlike die casting, the Injection Molding process reduces shrinkage during solidification, ensuring an especially high dimensional accuracy of the components. Injection Molding also reduces the porosity of the components, which is reflected in a higher density and stability.


Several factors that make up the Injection Molding process also help to reduce production costs: less energy is needed to achieve the thixotropic status of the magnesium alloy, the materials used in the process – machines, die, magnesium alloys – have a lower thermal load, and reject components are recycled. By lowering the processing temperature for example power consumption is reduced by up to 25%.


Injection Molding also allows for thinner wall thickness and complex, delicate structures, while still maintaining the same low level of power consumption.


The main advantages of Injection Molding are:
  • 100% recyclable
  • 33% lighter than aluminum
  • Wall thickness below 1 mm possible
  • Better thermal properties than polymer materials
  • High density, low porosity components
  • Suitable for safety-related and surface-relevant applications
  • Improved wear and corrosion resistance through surface treatment
  • Closed, single-stage process
  • Better dimensional stability, and therefore no milling necessary
  • Reduced draft angles
  • Weldable and heat-treatable


Current applications for Injection Molding:
  • Automotive industry
  • Computer industry
  • Electronics industry
  • Aircraft engineering
  • Medical engineering
  • Optics


Injection Molding Parts:
  • Seat components (arm rests and back rests, seat frames, etc.)
  • Steering wheels and steering column adapters
  • Structural and visual elements for convertible tops
  • Electronics and display cases
  • Cylinder head cover
  • Oil pans
  • Center console and instrument panel
  • Field glasses


The main differences between Injection Molding and magnesium die casting:
  • Shorter cycle time
  • Less material usage
  • Shorter flow paths
  • No pore formation
  • No gas inclusion
  • Improved part quality and part properties
  • Lower shrinkage, increased toughness
  • Improvement of mechanical and thermal properties compared to other metals and many types of plastics
  • Closed production – no waste
  • Dimensional stability improved, and therefore no milling necessary
  • Lower draft angles

The advantages of Injection Molding in production
  • No furnace or dosing
  • No piston lubrication
  • No SF6 gas protection
  • Clean manufacturing through the closed process