HotFlo!, have developed a systematic method to implement hot sprue technology based on experience in working with customers, knowledge of the die casting industry and the benefits of good documentation.

Follow these ten easy steps for a successful implementation in your plant:

1. Contact HotFlo!

Contact HotFlo! as soon as possible to register your interest. By doing this we will be aware of your investigations and can assist by answering specific questions relevent to your application.

2. Select a suitable component

If this is your first introduction to hot sprue technology, there are a number of issues to consider.

3. Collect Data

Information on the component, its application, and the machine on which it will be made, will ensure that all aspects are considered in the die. This is an important part of the "Die Design Inputs" procedure. A simple form has been developed to assist this process which can be emailed or faxed to Hotflo engineering staff.

4. Capability Analysis

All technical aspects of the project need to be analysed to ensure process capability and to verify the die design parameters. This can be done manually, or with the aid of software such as DC-CALC. Engineering staff from HotFlo can assist with this.

5. Die Layout Drawing and Review

A preliminary die layout drawing is prepared, showing the cavity positions, gate location, moving slides, die thickness and general dimensions. It may start as a series of simple sketches, but it is recommended that its final form is created with a good 2-D CAD system. It can then be emailed to and from HotFlo engineering, tooling subcontractors and the die caster.

The layout drawing is reviewed by production and tooling staff as well as HotFlo engineering and becomes the basis of the detailed die design.

6. Detailed Die Drawing and Check List

A final detailed die drawing can then be made showing all features and dimensions of the die including runner dimensions, die venting, die cooling, die heating, electrical connections, insulation materials, thermocouple location, ejection and all cores. A checklist should be used, and all parties should sign off to signify a verified die design.

7. Quotations for tooling and components

At this stage quotations can be called for the die casting die, trim tool where applicable, as well as any jigs, fixtures and other tooling components such as the hot sprue system and temperature controllers.

This is the best time to obtain quotations because the detailed die design can be given to suppliers ensuring that they all quote on the same specifications.

HotFlo engineering staff can also supply a quotation for the tooling if required.

8. Die Ordering and Manufacture

Once the make versus buy decisions have been made, orders can be placed and the manufacture of the tooling can proceed.

All the components needed for the trial must be ordered for delivery at the appropriate time, including : -

• the die
• the hot sprue kit or components
• a temperatute controller
• electrical connections (plugs, sockets and wiring in the die, and sockets to connect a temperature controller)
• a machine nozzle with the correct bore and spherical radius or conical tip.

9. Die Trialling and Review

Ensure that the die trial is well planned, and the right people are involved. Double check that everything is available before the trial.

The hot sprue fitment is adjusted for thermal expansion on the test bench first.

The correct machine nozzle is selected, the temperature controller is connected to the hot sprue and the brought up to operating temperature following the warm up procedure. The die trial can then proceed and all relevent data is recorded and off tool samples kept for analysis (including runner system).

Parts are checked for dimensional accuracy and process quality. Final modifications are made to any non-conforming features and the die is retrialled.

Document the results of the die trial. Evaluate the results of the die trial and discuss widely within the plant. Note all successful outcomes. Investigate any shortfalls or unsatisfactory results. Determine if they are related to the hot sprue technology or due to some other factor.

10. Release for Production

When all parts conform to the specification and machine production rates can be achieved, the die can be released to the plant for production.

The benefits of the hot sprue system can then be assessed, quantified and discussed.

Once you have had some hands-on experience with the HotFlo! technology, you will be in a good position to plan a wider implementation. Each new Die Casting die that is required should be designed to take advantage of this new technology. As they are implemented, you will gain further valuable experience of what works best in your plant.