Advantages of Rheocasting
at one glance

Up to 60 % less weight

Up to 60 % less weight

compared to steel parts of the same size. Areas of application: Vehicle components, chassis parts, crash-relevant parts.

Optimum mechanical strength and elongation

Optimum mechanical strength and elongation

Higher fatigue strength than steel. Areas of application: Vehicle components, chassis parts, crash-relevant parts.

Best weldability and pressure density (helium density)

Best weldability and pressure density (helium density)

Areas of application: Vehicle components, chassis parts, pressure vessels, radiators, pumps.

Best thermal and electrical conductivity

Best thermal and electrical conductivity

20 % higher thermal conductivity, improved EMC properties, best for applications in telecommunications and battery technology/power electronics

Cost-effective because of net-shape

Cost-effective because of net-shape

No milling, deburring, grinding necessary. Areas of application: Visible components, interior parts, brakes.

Allows wall thickness transitions and freedom of design

Allows wall thickness transitions and freedom of design

Any design possible, even for components with different wall thicknesses, e.g. in the field of bionics. Best functional integration, weight optimization at equal installation space.

Rheocasting By Sag Scaled Aspect Ratio 8 10
Rheocasting

Rheocasting components bring lightness to vehicle construction

Innovative technologies for processing light metal alloys have undergone enormous development in recent years. These include rheocasting – a special casting process in which aluminium in a semi-solid state is processed into lightweight components with special material properties.

SAG is the technology leader in rheocasting – a special casting process in which aluminium is cast in a semi-solid or semi-liquid state. This so-called semi-solid process has many advantages.

SAG is the only manufacturer in the world to produce rheocasting components such as safety cabin suspensions for trucks or air reservoirs in series production for the automotive industry. The demand for the light and particularly robust components is increasing strongly and the production capacities at the SAG location in Lend have recently been expanded considerably thanks to great demand from the passenger car industry. A total of more than EUR 3.6 million was invested in the expansion of the rheocasting facilities.

At the SAG plant in Sweden, more than 250,000 rheocasting components are produced annually in 3-shift operation for large truck manufacturers such as VOLVO and Scania.

In Lend/Salzburg, special components for the automotive industry are produced using the rheocasting process.

Because with only 3 parts (example: truck cab suspension) up to 120 kg weight – compared to steel parts – can be saved, thus reducing fuel consumption and saving an average of 0.3 tons of CO2 per year and truck).

Rheocasting thus offers a total package of advantages, for which VOLVO has awarded an innovation prize to SAG in 2018.

Find out more about rheocasting

More information about technical details in our Whitepaper “Semi-Solid Casting of Aluminium from an Industrial Point of View”

Find out more about rheocasting