Integral insert/liner is our unique, patented solution for sleeve cost optimization. It is a single-body HPDC component made of a special alloy, used as insert/lining of shoot sleeve to extend its in-service lifetime and decrease the frequency of shot sleeve replacements substantially.
Integral insert/liner is a special component used for protection of the sleeve across whole diameter and length.
It is a single body component produced using our specially developed wear-resistant alloy.
It is easily inserted and replaced in the sleeve with our custom made tool.
It is compatible with all kinds of shot sleeves (even existing ones can be adjusted) and does not influence the outer diameter of the sleeve.
It is highly customizable to specific customer requirements.
HTS Integral Insert / Liner inside thermoregulated envelope with 4 cooling circuits
Standard shape Integral Insert / Liner
Front 3D shape Integral Insert
Standard sleeve without integral insert
HTS Integral Insert / Liner
Envelope
HTS Integral Insert / Liner + Envelope
The shot sleeve is bored to form an envelope and a special integral insert/liner that covers the whole length of the sleeve gets inserted into the envelope
This way sleeve/envelope never comes into direct contact with molten alloy, so sleeve replacements are completely avoided. Insert/liner is the only component that needs to be replaced
Insert/liner gets replaced very quickly, in the case of smaller machines, it can be done directly on the machine, while in the case of larger ones, there is a special replacement tool we provide.
When using an integral insert/liner the cost of the envelope occurs only at the point of implementation.
As seen below, the difference in usage compared to conventional shot sleeves is that cost of the envelope occurs only once, at the implementation of integral insert solution and then, for each replacement only the insert/liner needs to be changed with a new one, while envelope remains unchanged.
HTS Integral insert/liner is made using the specially developed alloy that allows us to bring nitration layer hardness up to 1.250 Hvickers. This is 25% more than what can be reached when using traditional 1.2243/H11 or 1.2344/H13 made shot sleeves. Such difference in hardness translates into a substantially (up to 55%) longer lifetime than the conventional sleeves.
Nitration layer hardness (Hvickers)
Replacing the integral insert takes considerably less time than replacing the whole sleeve.
Smaller integral inserts can be replaced directly on the die casting machine, while for bigger ones we supply a special tool that makes insert replacement quick and easy.
HTS developed tool for integral insert replacement.
Using an Integral insert/liner to protect the shot sleeve, you save up to 30% on the cost of sleeves, because the number of sleeves required to complete a series is reduced substantially. In some specific cases, savings can reach up to 60%.
| DIMENSION | RANGE (mm) |
|---|---|
| Inner Diameter | 70 – 180 (larger diameters available on request) |
| Length | 400 – 1400 |
Based on the type of the sleeve, different mounting options are available
HTS Integral inserts are made using forged or rolled tool steel blocks produced in the EU.
The most often used grades are special HTS developed alloy or 1.2343/H11.
Based on specific customer needs, other steel grades can be used.
HEAT TREATED
HARDNESS between 44 and 50 HRC
MACHINED TO FINAL DIMENSION
NITRIDED
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