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Die Casting News

Largest high-pressure die casting machine in North America

Posted by Hill and Griffith Company on Apr 5, 2017 11:45:49 AM

Mercury Marine's new high-pressure die casting machine is now the largest in North America

high-pressure-die-casting-mercury-marine-1.jpgFOND DU LAC, Wis., April 3, 2017 -- Mercury Marine, the world's leading manufacturer of recreational marine engines held an event today to officially announce commissioning of the largest high-pressure die casting machine in North America. Since 2009, Mercury Marine has now invested more than $800MM in R&D and manufacturing expansion at its Fond du Lac campus. 

This specific investment is a 4,500 ton Buhler-Prince machine.  Installation began late in 2016 and was just completed in late March 2017.

"This new machine positions us to make castings that no one else in the industry can do," said Mike Meyer, general manager Mercury Castings. "With this new machine, Mercury can make larger, lightweight structural components and reduce the overall weight of our engine by producing more efficient castings."

(Photo from Lake County, Mercury Marine Dealer)

The new machine has 4,500 tons of closing force with three industrial robots integrated into the cell. The total weight of machine with tools and oil is more than one million pounds. The new machine can produce large, structural components for the high horse power marine segment, and even other segments such as automotive. "This new state-of-the-art casting machine is a great addition to our campus as it gives us the opportunity to continue to drive growth for the business said John Pfeifer, Mercury Marine president. "This investment is one of many milestones on Mercury's investment journey to support our customers now and into the future."

Additional features of the new die cast machine:

Integrated cell – automated to:
• Robotic metal pouring
• Robotic die lube spraying
• Robotic extraction from die cast machine
• Automated overflow detection to prevent damage to tooling
• Automated liner insertion into die cast machine
• Automated sawing of gates, eliminating ergonomic issues of lifting heavy castings/gating by operator
• Automated knockoff of venting and overflows, eliminating repetitive motion of hammering by operator
• Integrated part marking with 2D barcodes for part traceability throughout the product life

Hood Filtration System
• Integrated hood system to capture process steam and vapors to be filtered before being re-introduced to the plant
• Produces the cleanest environment in the industry for our operators

• Highly engineered and complex die casting tools ran in the machine
• Utilization of pressurized hot water equipment (up to 300 degree F) and high pressure jet cooling lines (flow rates up to 500 PSI)
• Over 100 water lines to help keep the tool in thermal equilibrium during the process

Parts Produced in Cell
• Extremely complex and large aluminum die castings
• Ability to pour casting shots up to 200 lbs

largest-die-casting-machine-Mercury.jpgHeadquartered in Fond du Lac, Wis., Mercury Marine is the world's leading manufacturer of recreational marine propulsion engines. A $2 billion division of Brunswick Corporation (BC), Mercury provides engines, boats, services and parts for recreational, commercial and government marine applications, empowering boaters with products that are easy to use, extremely reliable and backed by the most dedicated customer support in the world.

Mercury's industry-leading brand portfolio includes Mercury and Mariner outboard engines; Mercury MerCruiser sterndrive and inboard packages; MotorGuide trolling motors; Mercury propellers; Mercury inflatable boats; Mercury SmartCraft electronics; Attwood marine parts; Land 'N Sea marine parts distribution; and Mercury and Quicksilver parts and oils. More information is available at mercurymarine.com.

Mercury Press Contact:
Lee Gordon
Director of Global Public Relations


Tags: Die Casting, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent Mold Coatings


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