Development of PentaCast HPDC Technology Using Graphite Inserts

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PentaCast, in Strathroy, ON is a die casting foundry making zinc and aluminum automotive components, using High Pressure Die**Casting (HPDC) with steel molds and gravity cast into semi-permanent molds. The PentaCast will collaborate with the University**of Windsor' Metal Casting and Post Processing Technology group that have an extensive expertise and technical capabilities in**the area of HPDC and Rapid Prototyping (RP) of metallurgical processes including die cooling system.**The PentaCast goal is to become domestic and global leader in the area of novel RP methodology involving both, (1) hybrid**HPDC with interchangeable graphite/steel inserts in a steel die and (2) plant-wide metallurgical processes.**In order to address rapid prototyping of graphite/steel inserts in a steel die, PentaCast plans to invest in a high-speed machining**CNC technology. Patented by the University researchers, the Universal Metallurgical Simulator and Analyzer (UMSA) platform will**be utilized for RP of alloy development, improvements and verification of chemistry, liquid and semi-solid melt processing (thermal**and chemical treatments), optimization of the die thermal management parameters and cast component heat treatment and**determination of test sample functional characteristics all of which leads to maximization of component functional performance.**The RP of graphite die inserts together with the UMSA rapid physical simulations of HPDC processes will significantly reduce**development time and expenses for new cast components, alloys and manufacturing processes. R&D outcomes from the UMSA**simulations will also provide thermal data needed for designing of the ultrafine structures and conversion of the airspace alloys to**automotive applications.