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Plunger Tips & Die Parts

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Copper Titanium Plunger Tips and Die Parts

Die Casting Industry Challenge – Rejection!

Plunger Tips

The plunger tip (or a piston) is a critical element of pressure die casting process. The function of the plunger tip is to push the molten alloy into the mould repeatedly for extended number of cycles.

Its successful operation depends on several factors. One of the important factors is its effective interaction between a carefully machined and thermally stable shot sleeve.

A key factor to high performance plunger tip is to have a combination high hardness and good thermal conductivity. High hardness provides for high wear resistance which maintains dimensional stability between the plunger and shot sleeve. Material of the plunger tip should be able to dissipate its heat effectively to the circulating cooling water and maintain effective gap between the plunger and shot sleeve.

plunger tips

Plunger-Shot Sleeve Interaction

  • The interaction between the plunger tip and shot sleeve is the most critical in the die casting process. It can be only effective if both components are operating at equal level of efficiency.
  • The challenge is to maintain the least amount of gap without interference keeping in view the material of plunger tips and its co-efficient of thermal expansion and minimal use of lubrication.
  • The maximum gap between the plunger and shot sleeve should by 0.1 mm (100 microns) during the casting process.
  • The following properties are critical for a Plunger Shot Sleeve interaction for an effective working
    • Plunger Material
    • Enough Cooling inside plunger.
    • Alignment of Plunger and Shot Sleeve
    • Effective Lubrication
    • Clean Shot Sleeve
    • Shot Sleeve – Plunger Tip Clearance.

Copper Titanium Plunger Tips

QTi® Plunger Tips are manufactured from an innovative Copper Titanium alloy which has an excellent combination of high wear resistance and thermal conductivity which gives an exceptionally long life of plunger, making it an ideal material for Pressure Die Casting (PDC) Plunger Tips.

Copper Titanium Plunger tips are 100% Beryllium Free and can be easily machined to make smaller diameter plungers without any risk of exposure to Beryllium diseases.

To further enhance the life of plungers, we have adopted an innovative approach of providing a PVD coating to the plunger body which further enhance the surface wear resistance, without affecting the thermal conductivity of the plunger. Coated Copper Titanium plungers have given life over 40,000 shots.

QTi® Plunger Tips are manufactured as per our customer drawing and are available from Diameter 40 mm to 200 mm.
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Key Features

beryllium-free

Beryllium Free

Copper Titanium tools are made from high quality Copper & Titanium and is 100% free from Beryllium.

high-hardness

High Hardness

Copper Titanium Non-Sparking Tools have manufactured have hardness ranging from 260 to 320 BHN.

Good Conductivity

Good Conductivity

Copper Titanium material exhibits good thermal & electrical conductivity, which make it an ideal material for welding & thermal deposition application.

high-strength

High Strength

Copper Titanium tools have good strength and durability of tools. All Copper Titanium tools are torque tested.

High Temperature Performance

Corrosion Resistance

Copper Titanium tools offer superior corrosion resistance.

environmentally-friendly

Environment Friendly

Beryllium is one of the most dangerous and toxic metal being disposed in the environment Copper Titanium being 100% free from Beryllium pose non-such environmental risks.

Copper Titanium Plunger Tips

  • Delivers Plunger life of 25,000 to 50,000 shots (depending on the
    quality of interacting shot sleeve and machine alignment)
  • Offers lowest cost per shot.
  • Reduce rejection rates.
  • Increase Production Capacity with Zero Capital Investment.
  • Non-Hazardous, Safe to Use

Copper Titanium
Plunger Tips
delivers
LOWEST COST
PER SHOT

Existing Solutions of Plunger Tips

CAST
IRON

Majority of Die-Casters in India, use Cast Iron plungers because of its low initial cost. However, Cast Iron is a very poor thermal conductor and has low hardness and therefore CI plungers wear out very quickly in about 1000 shots. This leads to high rejection rate of casting and high down time.

COPPER
BERYLLIUM

Some Die-Casters use Solid Copper Beryllium tips, which have a simple design like cast iron, but are expensive and hazardous to handle, due to the presence of Beryllium in these tips. Many counties have banned or severely restricted use of Copper Beryllium due to the serious health hazard they pose to the users.

HYBRID
TIPS

Few Die-Casters use hybrid tip assemblies of a complex design with steel and copper alloy parts. These tips are very expensive and difficult to use and maintain.This leads to high rejection rate This leads to high rejection rate to high rejection rate rate rejection rate rate

Copper Titanium Die Part and Inserts

Tool steels, although high in hardness, have low thermal conductivity, and, therefore, cannot rapidly remove heat from non-solidified molten metal before flashing occurs. Since both high hardness and superior thermal conductivity are critical requisites in achieving accelerated cooling of molten metal under high pressure, it has been considered that copper alloys would provide superior thermal conductivity.

However, few copper alloys provide both thermal conductivity and hardness in combination enough to withstand the pressure that results in die casting molten metal.

Copper Titanium Core Pins / Inserts

Core pins are subjected to high thermal and mechanical stresses in GDC, LPDC & HPDC Casting process. Core Pins made of steel are unable to extract heat quickly due to its poor thermal conductivity leading to shrinkage and porosity in the casting.

Copper Titanium Core Pins and Inserts provide highest combination of thermal conductivity and strength. QTi Inserts are much stronger than other competing copper alloys and exhibit thermal conductivity up to 5 times greater than steel pins. High hardness of Copper Titanium alloy provides excellent wear resistance. This significantly increases the life of the Pin.

The high-copper alloy provides excellent corrosion resistance and inherent lubricity and galling resistance. By providing a coating of hard PVD coating on the surface of Copper Titanium core pin increases its surface wear resistance and thereby increasing the life of the pin.

Copper Titanium Chill Block and Vents

Chill-Vents are often used in permanent moulds of Aluminium and Magnesium Die castings which functions when charging a molten metal into the mould cavity, to efficiently remove residual air and/or gas from inside to outside of the cavity, without spouting the molten metal or flashing. When air and/or gas is left in the cavity of the permanent mold at the time of die-casting, the air or gas tends to be dragged into the molten metal so as to cause gas holes and the like defects in the products and thereby degrade the product quality. Copper Titanium is 100% Beryllium free material and exhibit excellent thermal conductivity and has high strength making it the preferred material for Chill Vents/Chill Blocks

Chill-Block

Advantages of using Copper Titanium Core Pins, Chill Blocks and Vents

  • Eliminate / Reduce casting rejections due to porosity or cold shuts.
  • Improve Die cooling – Reduce Cycle Times.
  • Easy to machine and embed as inserts in dies.
  • Beryllium free, Non-Hazardous, Safe to Use, Environment friendly
  • Reduction of machine downtimes.
  • Increase life of the mould components (for instance core pins).
  • Improvement of the surface and dimensional quality of the manufactured part.
  • Distortion control.

Copper Titanium
Core Pins
Chill Blocks
Vents

Beryllium free

Get More with Copper Titanium

While Copper Titanium offers its unique advantages, we go an extra mile to help our customer save that extra $.

We have the capability of providing near net shapes of the dies and moulds inserts based on the drawings, thereby saving upto 60% on material and machining cost.

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plungertips-form

Increase Productivity in your facility

Find out how you can reduce rejections and improve productivity with QTi® High Performance Plungers Tips and Die Parts

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