Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces and are suitable for a wide variety of finishes. The production process includes the following steps:  1. Furnaces melt the aluminum ingot 2. The molten aluminum is then transported to the appropriate die casting station where it is poured into a smaller holding furnace.  3. The molten metal is injected into a die under pressure.  4. The metal quickly solidifies into the shape of the die and the cast part is then removed.  5. Depending on the specifications of the part, machining equipment is used to complete the manufacturing of the part.

Revstone produces geometrically complex aluminum die casting products that offer substantial process technology such as enhanced performance, weight reduction, and cost savings. The Company’s technology processes, ranging from lowest technology content to highest, include High Pressure Die Casting (“HPDC”), Horizontal Squeeze Casting (P2000H), Vertical Squeeze Casting (P2000V), and High-Q Cast (ThinTech).

High Pressure Die Casting

High pressure die casting has the following advantage over traditional die casting: wider application, encompasses nearly 50% of all light alloy casting products and use is increasing, provides castings that require tight tolerances and detailed geometry, produces castings that are very durable and have excellent electrical and metal properties, cost effectiveness, are among the highest volume, mass produced items manufactured by the metal working industry, can be produced with smooth or textured surfaces, and can be easily plated or finished with a minimum of service preparation.

Revstone differentiates itself within the marketplace by providing focus on the highly technological and detailed products that are difficult to manufacture. The company specializes in products with defined and unique shapes that differ from the products of competitors.

ThinTech

In this unique process, a high level of vacuum is achieved in the die cavity and shot chamber prior to the injection of metal. Advanced vacuum monitoring techniques are utilized to ensure proper functioning of the vacuum system. This high level of vacuum coupled with a rigorous metal handling process results in ThinTech components that exhibit very low levels of entrapped gas. This low gas level allows subsequent processing that until now was not compatible with high pressure die castings. The integrity of the castings, further enhanced by heat treating, result in high performance components for a variety of applications.  

Castings produced by the ThinTech process are suitable for structural applications as well as for Chassis and Suspension systems. 

The Company is the only North American supplier capable of a full range of thick to thin wall castings. These castings can range anywhere from 2-4mm thin to greater than 10mm thick. Revstone has produced the BMW X5/X6 Shock Tower using the ThinTech Cast Process. In this process, the piece (specifically the BMW X5/X6), is 40% lighter than the traditional steel shock tower, which includes seven steel stampings. As more European Automotive Manufacturers (VW, Audi, Mercedes), which use lighter products, implement manufacturing facilities in the U.S. there will be more opportunities for Revstone to supply their ThinTech process. Revstone currently has three machines that can produce ThinTech products while competitors only have one.

The ThinTech process can also replacing steel stampings in the car body and chassis. Car bodies represent approximately one quarter of the vehicle weight and offers the greatest potential for weight savings. Reduced body weight results in opportunities to reduce the size / weight of other components throughout the vehicle (engine, brakes, suspension, etc.). In addition, using aluminum instead of the steel equivalent for the car body and chassis can save up to 50% of a car body structure weight and still match or exceed structural stiffness and crashworthiness requirements.  

Revstone supplies the automotive, appliance, and industrial industries with die cast parts. Example automotive parts include: Fan Clutch Housings & Impellers, Belt Tensioner Housings & Arms, Truck Brake housings, Air Compressor Components, Truck Axle Hub Caps, Truck Brake Valves, rack and pinion housings, PTU housings, shift drums, axle carriers and covers, and column parts. Other products include: Gas Water Heater Valves, Industrial HVAC Control Valves, Industrial Glue Machine Components, Concert Lighting Housings, and Light Fixture Components.

Revstone Contech holds ten U.S. patents related to casting process technology. 

Revstone companies that specialize in this process include:

-Revstone Contech

-Revstone Texas Die Casting

For more information or to request a quote for your Die Casting business, please contact:

-Myra Moreland - mmoreland@revstone.com