Weltpremiere für den Zwei-Komponenten-AMM-Prozess auf der K 2019: Die Silikondichtung wird an die Gehäuseteile aus amorphem Metall direkt angespritzt.
Bildquelle: alle Engel

Weltpremiere für den Zwei-Komponenten-AMM-Prozess auf der K 2019: Die Silikondichtung wird an die Gehäuseteile aus amorphem Metall direkt angespritzt.
Bildquelle: alle Engel

Due to their randomly arranged, non-crystalline structure, amorphous metals are both extremely hard and highly elastic. They have very good elastic recovery, are extremely corrosion resistant and biocompatible according to ISO 10993-5. With this combination of properties, these alloys are superior to steel, titanium and many other materials. On the basis of its proven hydraulic and tiebarless Victory range, Engel has developed a new injection moulding machine for processing amorphous metals from Heraeus’ Amloy product range. The Victory AMM (amorphous metal moulding) delivers fit-for-purpose parts with a premium quality surface finish within very short cycle times.

Fully automated process

For the production of two-component housing demo parts at the K show, Engel is combining a Victory 120 AMM with an insert 60V/45 vertical injection moulding machine, which is equipped with a two-station rotary table. The manufacturing cell is fitted with both an Viper linear robot and an Easix articulated robot for the fully automated production process.
The first step involves injection-moulding the basic structure for the housing on the Victory AMM from a zirconium-based Amloy alloy. To do this, the viper robot takes an Amloy pre-material from the separator and transfers it to the injection unit. After less than 70 seconds, the metal component takes full shape. The viper removes the part and deposits it onto a tray. The easix articulated robot takes over from there, placing the Amloy component on the lower mould half on the insert machine’s rotary table, where a liquid silicone rubber (LSR) seal is moulded on the part. The elastomer component also consistently fills out the seal structure on the bottom of the part through narrow openings on the surface of the housing. The mould for the AMM process was provided by Flex, while Starlim Sterner supplied the LSR injection mould for the K show.

Geared for high-volume production

The demo parts combine the needs of portable electronic devices with the innovative properties of the Amloy materials. In addition, two-component injection moulding opens up new opportunities for designing housing frames that are almost indestructible while enjoying better protection from dust, water and radio waves.
Zirconium-based and copper-based alloys for large-scale applications are currently available in the Amloy product line, with alloys based on titanium, iron and platinum also in the works. With this variety of materials, Heraeus and Engel cover a huge range of new applications. The list includes portable electronic devices, durable instruments for minimally invasive surgery, stable suspension and wear-resistant drivetrain components for the aerospace industry, premium decor elements for cars, and abrasion-resistant watch components.

K 2019 Hall 15 Booth C 58

About the author

Leopold Praher

Verkaufsleiter elast/LIM