{"id":8562,"date":"2025-02-01T16:33:57","date_gmt":"2025-02-01T16:33:57","guid":{"rendered":"https:\/\/www.jstconsultancy.cz\/?p=8562"},"modified":"2026-08-01T05:41:47","modified_gmt":"2026-08-01T05:41:47","slug":"global-giga-casting-congress","status":"publish","type":"post","link":"https:\/\/intelligent-kalam.80-240-27-133.plesk.page\/en\/global-giga-casting-congress\/","title":{"rendered":"Global Giga Casting Congress"},"content":{"rendered":"

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GIGA casting is starting to take off in all directions. On March 5th and 6th, the Global GIGA-CASTING Congress<\/strong> will be held in Kassel, Germany, at the local University. You can find the program here:
\nhttps:\/\/www.uni-kassel.de\/maschinenbau\/institute\/produktionstechnik-und-logistik\/fachgebiete\/giessereitechnik\/global-giga-casting-congress-2025\/program<\/a><\/p>\n

According to Forbes (https:\/\/www.forbes.com\/councils\/forbesbusinesscouncil\/2024\/09\/03\/the-gigacasting-question-innovation-vs-investment-in-auto-production\/<\/a>) the global die casting market is set to grow from $82.86 billion in 2024 to a staggering $112.14 billion by 2029 at a CAGR of 6.24%. This growth is driven by the demand for lightweight, high-strength castings to improve fuel efficiency and reduce emissions.<\/p>\n

However, the Gigacasting industry is evolving even faster, with projections showing a meteoric rise to $2.6 billion by 2030. By then, more than 10 million vehicles are expected to feature large die cast parts, with electric vehicles leading the trend.<\/p>\n

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Casting warehouse at Tesla in Texas\u2026..<\/p>\n

https:\/\/x.com\/JoeTegtmeyer\/status\/1863714636782051628?utm_source=lucagreco.beehiiv.com&utm_medium=referral&utm_campaign=weekly-gigacasting-news-17<\/a><\/p>\n

Only one contribution in the program concerns tools, \u201cLatest developments and solutions at MEGA\/GIGA-HPDC molds, Siegfried Heinrich, Schaufler Tooling GmbH & Co. KG (DE)<\/strong>\u201d. (https:\/\/schaufler.de\/). Schaufler is basically the only traceable tool shop specializing in GIGA tools today in Europe.<\/p>\n

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The picture is from the tool shop website https:\/\/schaufler.de\/<\/a> – the condition for producing such large molds is a 120-ton crane and a 200-ton tryout press. However, there is no mention of heat treatment. So, it remains a closely guarded secret. One can only assume that there is \u2026<\/p>\n

Today’s standard is already GIGA presses with a clamping force of up to 9,000 tons<\/strong>, but from the next image it does not end there. If the goal is to be 1 car = 1 part from HPDC technology, then they will need to build presses with a clamping force of up to 20,000 kg.<\/strong><\/p>\n

Graph showing the dependence of the frequency of parts from HPDC technology in a car of various concepts on the clamping force of the GIGA press according to the publication: \u201cMega-casting in the automotive production system: Expert interview-based impact analysis of large-format aluminum high-pressure die-casting (HPDC) on the vehicle production.\u201d (https:\/\/www.sciencedirect.com\/science\/article\/pii\/S152661252400608X<\/a>)<\/div>\n
<\/div>\n
Athough I can imagine this with a GIGA press, not so much with vacuum furnaces. We will encounter the ability of such a vacuum furnace to cool shaped parts at a rate higher than 28 C\/min, i.e. the physical barriers of the steel material and the furnace design.<\/div>\n
\nIt will therefore be necessary for the designer of such a GIGA tools to think about this already during its design, and divide it in the dividing plane into inserts that will not exceed the critical weight or size. And what is the critical weight? I thought about it a little in my blog https:\/\/intelligent-kalam.80-240-27-133.plesk.page\/mega-nebo-giga-die-casting\/<\/a><\/div>\n
\nStrangely, Nadca 207:2022 is silent about this. This does not bode well, because the trial-and-error method will not be applicable here. The price of the die is in the order of millions of USD, the price of the corresponding vacuum furnace for hardening will be close to 2 million USD. Too much money for an uncertain result. So, it is a mystery to me that GIGA casting is already being implemented, but finding detailed information is simply impossible for now. I have also tried ChatGBT, DeepSeek,<\/strong> but I am getting into a closed circle. It offers me my own articles on the blog.<\/div>\n

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It can therefore only be assumed that these GIGA moulds made of H11 or H13 material will not be very suitable for this application, and for now the only material that can satisfy this requirement is Dievar from Uddeholm. To avoid the carbide nose and the bainite area, we must achieve cooling from the austenitizing temperature to 540 C in 18 minutes according to Nadca 207:2022.<\/strong> This can only be 100% guaranteed for bodies up to 200 mm thick. Given the CCT diagram of this steel, even a 300 mm cross-section will have a chance of good toughness and therefore resistance to thermal fatigue. With an insert size of 1000x1000x300 mm, this is a weight of up to 2.6 tons. However, inserts with a thickness greater than 300 mm will already be on the verge of hardenability.<\/p>\n

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Unfortunately, I will not be able to attend the congress, it conflicts with the spring vacation at school. I am sorry, I would really like to hear it. After all, the idea that in a brief time 10 million cars will be produced using this method per year suggests that this is a real trend. And it is not over yet…. maybe next time<\/p>\n

Ji\u0159\u00ed Stanislav<\/p>\n

February 1,\u00a0 2025<\/p>\n

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