The Leonardo3 Museum, a one-of-a-kind museum dedicated to the Renaissance master, artist, and inventor, located in the stunning setting of Galleria Vittorio Emanuele II in Milan, approached Bruschi at the end of 2023. The museum requested Bruschi’s collaboration with the Leonardo3 Research Center team to realize the project. After a year of work, the masterpiece was completed, allowing museum visitors to witness the realization of the maestro’s vision.

The Leonardo3 Museum reveals the true genius of Leonardo da Vinci as an artist and inventor through groundbreaking reconstructions of his machines and restorations of his paintings. Bruschi was chosen for this exceptional project due to its technical expertise and capabilities, which proved essential in bringing this extraordinary piece to fruition.

Bruschi was selected by the museum to manufacture the individual components of the structure based on designs created by the Leonardo3 Museum Study Center, which then reproduced the master’s work in its workshops.

The design of the Mazzocchio, also known as a “hood-shaped” structure, served as the foundation for a headpiece commonly worn in Renaissance Europe. More importantly, it has fascinated and challenged artists, designers, and engineers for centuries, inviting them to explore its unique perspective. Notable examples include the illustrations of Piero della Francesca and the intarsia work of Federico da Montefeltro.

Copyright of images: Leonardo3 Museum – All rights reserved.

The Mazzocchio’s structure is highly complex. It represents an axonometric projection, where each plane of the toroidal solid, composed of octagonal sections, forms a hollow structure that reveals the layers beneath it. Essentially, it is a polygonal ring made up of a series of hexagonal or octagonal prismatic sections, joined to form obtuse angles throughout.

For the first time in history, Bruschi, in collaboration with the Leonardo3 Research Center, constructed this structure in metal. It is now on display at the museum in Milan, exhibited alongside Leonardo’s original drawing, preserved in the Codex Atlanticus.

Paolo Rastelli, CEO of Bruschi, shared his pride in the accomplishment:
“As an engineer, I am immensely proud that Bruschi has contributed to such an important endeavor. Beyond the technical and technological expertise required, it is incredible to witness a Leonardo masterpiece come to life. We are honored to have partnered with the Leonardo3 Museum to realize this vision of the maestro.”

The Mazzocchio is exclusively on display at the Leonardo3 Museum in Milan.

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One year after the acquisition of Sapre, the two companies will become one: Sapre will be fully incorporated into Bruschi, creating a single, stronger, and more competitive organization in the manufacturing and innovation sectors.

With this merger, Bruschi officially expands its expertise by adding aluminum alloy die-casting technology to its portfolio while maintaining its long-standing leadership in zinc alloy die-casting. This integration brings together a network of 240 skilled professionals across two Italian facilities and the Milwaukee (USA) office, all collaborating to deliver innovative solutions to customers worldwide.

To reflect this transformation, Bruschi has also updated its legal name to Bruschi S.r.l., underscoring its commitment to simplifying processes. For over 75 years, Bruschi has been a flexible and agile organization, ready to lead change in the die-casting industry.

Paolo Rastelli, CEO of Bruschi, commented:
“The completion of this merger allows us to warmly welcome our new colleagues to the team. This process streamlining will make us more agile in the market, enabling us to reduce Time to Market and offer even more specialized expertise to support our customers in achieving their goals. Bruschi has always placed the customer at the center of its strategy, building on the trust that drives goods and people through factories worldwide.”

Bruschi was supported in this transaction by TCA Triberti Colombo e Associati, serving as its advisor. The company extends its heartfelt thanks to Dr. Paolo Bergamasco and Attorney Nicola Salvarani for their invaluable contributions.

This merger marks an exciting new chapter for Bruschi, reinforcing its position as a leader in innovation and manufacturing excellence.

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We’re thrilled by the high level of interest and the questions that enriched the discussion, allowing for a direct exchange on real cases and daily challenges in the industry. A special thanks to our internal experts: Matteo Margiri, Andrea Panvini, Ermo Fusè, Matteo Colombo, and Marco Scaramuccia, for offering concrete insights drawn from their experience at Bruschi foundries, making the webinar even more relevant and practical.

Stay tuned for future in-depth events and updates on industry developments.

Thank you once again for your participation and interest!

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The component in question is linked to the safety of the vehicle’s driver and passengers. Due to its very nature, it requires a maximum tolerance of a few thousandths compared to the required weight of 6 grams. Such a tight tolerance level is challenging to be respected 100% in producing die-cast parts.

Bruschi’s R&D team and technical office took the lead in developing a pioneering project in the sector. Leveraging software development and cutting-edge technologies, they overcame the common limitations of die-casting production and met the customer’s demand.

Therefore, the mass production of zinc pieces smaller than a €1 coin was guaranteed, respecting the tolerance specifications provided by the customer.

Bruschi designed and implemented a fully automated production process to ensure precision and quality. This process involves the use of robots equipped with precision grippers capable of extracting the die-cast components from the molds. A camera placed on the machine allows the robot to independently verify the presence of all the pieces inside the mold, dismantle them, and place them on a precision scale for quality assurance.

Any pieces that do not meet weight standards activate a reject system.

This is an example of how technological progress and engineering skills make it possible to satisfy the market’s needs, overcoming production limits that only a constantly evolving company can overcome.

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Zinc alloys are renowned for their remarkable properties such as their robustness, resistance to corrosion and ease of casting. Over time, the evolution of manufacturing techniques has propelled zinc alloys to the forefront of a wide range of industries, including the automotive and electronics sectors. In this post, we will provide insights into the latest advancements unfolding within the realm of zinc alloys and their development, shifting from cutting-edge innovations to manufacturing breakthroughs. 

Furthermore, we will delve into how these materials will unlock new opportunities and enhance performance standards by revolutionising product development across various sectors.

Lately, slight fluctuations in zinc alloy demand have arisen due to economic slowdowns and changes in global industrial demand trends. Despite these challenges, the ever-expanding automotive industry has remained a constant driver of demand for zinc alloys. Utilization of zinc alloys in critical processes such as die-casting has been instrumental in meeting industry performance and durability standards. As the automotive industry continues to evolve and adapt to changing market dynamics, the role of zinc alloys remains important, providing manufacturers with a versatile and reliable solution to meet evolving industry demands while fostering innovation and sustainability in the manufacturing sectors.

Alongside their mechanical properties, zinc alloys are also valued for their environmental sustainability. Zinc is highly recyclable: recycling rates of zinc alloys have soared to nearly 80% globally. The metal’s recyclability ensures conservation of natural resources and the reduction of energy consumption (and subsequent greenhouse gases emissions) associated with primary metal production, classifying it as an eco-friendly choice for manufacturers aiming to minimize their environmental footprint.
A brief rundown of zinc’s most advantageous properties has been given below.

Qualities of zinc alloys

• Strength and durability

Over time, significant progress has been made in enhancing the strength and durability of zinc alloys. Through precise alloying and innovative processing techniques, researchers have been able to achieve remarkable progress in crafting alloys with higher resistance and improved robustness, which represent significant breakthroughs in the industry. This has expanded the utility of zinc alloys across a spectrum of growing sectors all over the world, immensely benefitting manufacturers. Production of components is now able to more effectively meet the stringent demands of buyers by ensuring greater degrees of performance and longevity.

Among the distinguished zinc alloys (like zamak 2, zamak 3, zamak 5 and zamak 8), zamak, composed by a mix of zinc, aluminium, magnesium and copper, emerges as a prominent contender. Zamak alloys are known for their exceptional strength and dimensional stability, making them perfectly suited for the fabrication of components requiring intricate shapes or stringent tolerances. The versatility inherent in zinc alloys empowers designers and engineers with a variety of options in material selection. Zinc alloys can be specifically tailored to meet specific performance needs, offering a customizable solution that seamlessly aligns with all the needs of its diverse applications. This flexibility not only enhances the efficiency of manufacturing processes, but also underlines the pivotal role played by zinc alloys in driving innovation and unlocking new opportunities in engineering and design. 

• Corrosion resistance

In a wide variety of industries, especially the automotive and construction sectors, corrosion resistance stands as one of the key factors influencing buyers’ choice of material. Historically, zinc alloys have been recognised for their ability to withstand corrosion, owing to the formation of protective oxide layers on their surfaces. However, recent research and development practices have increased their corrosion resistance capacity to new heights, positioning zinc alloys as a leading material, capable of enduring the harshest of environments. These advancements have not only helped in the corrosion resistance property of zinc alloys, but have also significantly extended their service life, ensuring optimal performance in both favourable and challenging conditions.

Across the spectrum of zinc-based alloys, exceptional resistance to corrosion is a hallmark feature. This resilience makes zinc alloys indispensable in applications where exposure to corrosive elements is inevitable. Notably, the presence of aluminium in these alloys adds to their already robust corrosion resistance, further fortifying their suitability for a diverse array of environments. Whether exposed to road salts and harsh weather conditions when employed in automotive components, or atmospheric pollutants when utilized in structural elements of buildings, zinc alloys demonstrate unparalleled resilience, ensuring longevity and reliability. As industries continue to prioritize and value the durability of their products, the corrosion resistance of zinc alloys makes it one of its greatest assets, further helping it shape the landscape of modern engineering and construction practices.

• Customization

One of the most exciting advancements in zinc alloy technology is the capability to customize alloys according to specific application requirements. Through precise adjustments in composition and microstructure, engineers can tailor zinc alloys to yield desired properties like conductivity, thermal stability and resistance. This level of customization not only enhances the versatility of zinc alloys but also sparks innovation in product design. Manufacturers now have the freedom to create components that perfectly align with the demands of their respective industries, pushing the pre-existing boundaries present in the fields of engineering and design.

• Sustainable manufacturing

In the current climate of heightened environmental awareness, sustainability has become a primary consideration in the development of materials. Zinc alloys present numerous advantages in this context, which include their widespread availability, optimal recyclability and minimal energy consumption during processing. Recent initiatives have concentrated on enhancing the sustainability of zinc alloy production through the implementation of efficient recycling methods and the adoption of eco-friendly manufacturing processes. These efforts signify a commitment to reducing the environmental impact of zinc alloy manufacturing, further aligning with broader sustainability goals through responsible resource management.

Innovations in zinc alloy development

Advancements in zinc alloy development have paved the way for innovative applications across various industries. In the automotive sector, zinc alloys improve the safety mechanisms of vehicles and enhance crash performance. Zinc alloys are also finding their applications in the electronics industry and this is possible because of their excellent thermal and physical properties, such as conductivity and EMI (electro-magnetic interference) shielding. Additionally, zinc alloys are increasingly being adopted in the medical sector for surgical instruments and implants, benefiting from their biocompatibility and corrosion resistance.

The market for zinc alloys has been witnessing significant technological advancements such as additive manufacturing, which, paired with the advent of new material compositions, have helped expand the reach of zinc alloy applications. Companies in the sector are increasing research and development to create new alloys offering superior performance, energy efficiency and environmental benefits, all of which will come to the aid of manufacturers and customers alike.

Future outlook

Looking ahead, the future of zinc alloy development appears promising, with ongoing research focused on enhancing performance, expanding metal applications and boosting sustainability. With the help of advanced computational modelling techniques and additive manufacturing technologies, we can expect to see even greater innovation and diversification in the design and application of zinc alloys.
One of the key trends likely to shape the zinc alloy market is the increasing demand for sustainable and environmentally friendly materials. The alloys are anticipated to evolve in response to stricter environmental regulations and the push for greener materials in the manufacturing value chain.

Market forecasting is a critical component for businesses and investors looking to make informed decisions in this sector. Trends suggest a moderate growth trajectory for the zinc alloy market, with regional hotspots potentially altering market dynamics through accelerated demand and innovation.

Conclusion

In conclusion, the advancements in zinc alloy development marks a significant milestone in the realm of materials science and engineering. Extraordinary features of zinc alloys encompass strength, durability, remarkable customizability and sustainability, and enable zinc alloys to continually push the limits within modern manufacturing. As research and innovation continue to evolve, these materials are positioned to assume an increasingly important role in shaping the technologies of tomorrow.

The zinc alloy market stands as both essential and dynamic, thus exposing companies within the sector to a wide range of challenges, but most importantly opportunities. Through strategic decision making and the use of comprehensive data and analysis, players in the market can look to anticipate and capitalize on emerging trends, driving sustainability and profitability over the long term. With a proactive approach and an eye towards innovation, companies can ensure a prosperous and successful future for the zinc alloys market, as it promises to be one of the most resilient.

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In recent times, automotive manufacturers are more focused on manufacturing lightweight automobiles without affecting durability of the vehicles. Therefore, die casting is one of the most valuable techniques adopted by the manufacturers for creating automotive parts. The number of die cast parts used for automobiles continues to rise daily. Some of the main reasons for the increase in demand of die casting by the manufactures are:

Increased precision, efficiency and cost effectiveness

Die casting is a technology that helps in increasing precision, efficiency and cost effectiveness of the automobiles / vehicles that are getting manufactured by using die casted products or components. Die casting is also one of main reason behind numerous automotive advancements that are witnessed by all of us. With the ability to mold materials such as zinc, aluminum and magnesium alloys, die casting unlocks various other opportunities that helps in elevating vehicle performance boosting in an overall growth of automotive industry.

Helps in fuel efficiency

The inclusion of die cast components in the automobiles, mainly in engines, also helps in fuel efficiency as the overall weight of the vehicle reduces when die casted components are used which also results in lower emissions resulting in reduction of pollution and better vehicle performance that helps in production of more units effectively and efficiently.

Increased automation and flexibility

The popularity of automotive die casting is increasing day by day all over the globe due to the high use of advanced technology in almost every industry. All the process becomes more effective and productive when the production process is automated. Moreover, die casting technique helps to create parts with complex shapes and sizes easily which ultimately makes the installation process smoother.

As discussed above, die casting helps to produce parts with complex shapes with high durability and improved aesthetic appearances. Following are some of the parts / systems from wide variety of applications of die casting for automobiles that includes:

• Engine parts
• Mounting brackets for electric motors and stepper motors
• Electronic covers for gearbox
• Sensor and airbag housings as active safety mechanisms
• Fuel intake parts
• Air conditioning systems
• Mounting brackets for stepper motors
• Retractor spools for seatbelts
• Transmission components
• Sensors
• Chassis components
• Durable power steering and braking systems

Advancements in die casting technology

As automotive manufacturers strive to stay at the top of innovation and adapt to new technologies, die casting technology has evolved to meet the growing demands of the industry which also helps the manufacturers to product the vehicles with the new technology that also helps in customer satisfaction. Some of the main advanced die casting techniques are playing a crucial role in achieving higher levels of precision and efficiency in automotive industry such as:

1. High pressure die casting

High pressure die casting involves injecting molten metal into a steel mold at high pressures that results in faster cycle times and enhanced part integrity of the vehicles. This type of die casting technology helps in the production of complex automotive components with minimal porosity, ensuring the highest quality and durability.

2. Vacuum die casting

In vacuum die casting, the process is carried out in a controlled environment with reduced air pressure. This method minimizes gas porosity in the final product that is being produced, further also improving the structural integrity of the automotive components. In recent times, manufacturers are increasingly adopting to vacuum die casting for manufacturing the critical parts, such as engine components and safety mechanisms.

Innovations in die casting materials

With the aim to create light weight yet robust automotive components, die casting industry has witnessed continuous material innovations. The incorporation of advanced alloys, such as zinc – aluminum alloys, has become prevalent. These alloys not only offer improved strength and durability to the vehicles but also provide a higher degree of corrosion resistance to them. The composition of the materials can also be customised as per the requirements which results in enhancing the overall performance of die – cast automotive parts.

This customization capability not only focuses on specific performance requirements but also opens various opportunities to include die casting materials for diverse applications in manufacturing other different components for automobiles. As a result, the evolution of die casting materials is not just about meeting the current industry needs but also about anticipating and adapting to future technologies and challenges in the automotive manufacturing industry.

Sustainable practices in die casting

In response to growing environmental concerns among the individuals and manufacturers, the automotive industry along with various other industries is also increasingly focusing on sustainable practices for most of the processes. Die casting foundries are also collaborating with many automotive manufacturers to implement eco – friendly measures in their production and all other operations. This includes the use of energy – efficient equipments, recycling of process water and the implementation of green manufacturing practices. This aligns with the automotive industry’s commitment to reducing its carbon footprint.
By aligning the die casting processes with sustainability goals, the automotive industry is moving towards a more environmentally responsible approach that will not only help the environment but will also help the companies in the long run.

Future opportunities

In the ever – evolving industry of die casting, several new and trending opportunities are emerging which is helping to push the industry towards enhanced capabilities and efficiency. Let us have a look at some of the possible future opportunities that lies there for die casting industry with respect to automotive industry.

New materials and alloys

Research into new materials and alloys is opening opportunities for enhanced die casting capabilities. Materials with improved strength and durability are being explored to meet the evolving needs of the automotive industry that will help in the manufacturing of different types of parts and components for automobiles that will be having more stability and resistance to make the final product much better from now.

Smart manufacturing and industry 4.0

The integration of smart technologies and industry 4.0 principles enables real – time monitoring and control of die casting processes. Predictive maintenance, data analytics, estimation of demand – supply and automation contribute to increased efficiency and reduced downtime which helps in the overall growth of the manufacturers as well as of the automotive industry.

3D printing and prototyping

The unification of 3D printing technologies in die casting processes allows for rapid prototyping and the creation of complex geometries that are required in day-to-day basis in automotive industry. This innovation accelerates the product development cycle of the parts and components that are manufactured and supports the customization of automotive components.

Collaborative research and development

Collaboration between die casting manufacturers, automotive companies, and research institutions fosters a scope for continuous improvement. Shared knowledge and expertise can lead to breakthroughs in die casting technology that can also help in analysing the challenges that are faced in the correct manner and take corrective actions and measure to tackle them.

Conclusion

In conclusion, the innovation and efficiency in automotive industry has led to the widespread adoption of die casting techniques, particularly in the manufacturing of light weight and durable components. Die casting not only enhances precision, efficiency, and cost – effectiveness but also contributes to fuel efficiency, automation and flexibility in the production processes that are done for the production of parts and components of automobiles. The diverse applications of die casting in creating complex parts for engines, safety mechanisms and various automotive systems throws light on its pivotal role in shaping the future of the automotive sector with the help of die casting in the process.

The evolution of die casting technology, including high – pressure die casting and vacuum die casting, showcases the industry’s commitment to achieving higher levels of precision during the process of production. Material innovations for die casting are also resulting in contributing to create robust and lightweight automotive components. Moreover, the industry’s increasing focus on sustainable practices focuses on environmental concerns emphasizing a responsible approach towards reducing the carbon footprint.

Looking forward, the automotive industry anticipates exciting opportunities in the near future, including the exploration of new materials and alloys, the integration of smart manufacturing and industry 4.0 principles, the adoption of 3D printing for prototyping and collaborative research and development initiatives. The points mentioned above not only promises improved and enhanced die casting capabilities but also signifies a collective effort towards continuous improvement.

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The advantages of zinc die-casting

Before we delve into the importance of design, it is essential to understand the benefits of zinc die-casting. This manufacturing process allows for components with complex geometries, small, high-precision details, and thin walls, offering a wide range of design possibilities. Using zamak as a casting material offers, among various positive properties, good mechanical strength, effective resistance to corrosion, and excellent thermal and electrical conductivity. The above advantages facilitate the designer’s work in the search for the most suitable material and production system for the product in the design phase, offering various construction possibilities provided by a single alloy.

The excellence of design

Design is undoubtedly a crucial factor in the success of any product, and in zinc die casting, it is no different. Functional design is all about balancing form and function, combining aesthetics and practicality to create a product that is attractive, functional, and efficiently buildable. In the case of zamak die-casting, the shapes of the product must be designed considering the possibility of being obtained from a mold and the ease of filling the mold with liquid metal. This aspect represents a fundamental factor for an efficient production process, as we have analyzed in the post: Surface defects in zinc die casting: flow marks, blistering and sink

Engineers and designers must also consider several crucial aspects to achieve design excellence.

Features

The functionality of a product is the fundamental element. It is essential to understand the component’s technical specifications and ensure that the design meets these requirements. Just as it is important to verify that the die-casting production process allows the creation of the shapes identified in the design phase, this involves careful assessment of mechanical stresses, tolerances, thermal and electrical properties, and interactions with other components in the system.

Aesthetics

In addition to functionality, aesthetics play a significant role in zinc alloy die-cast products. Well-designed products must be aesthetically pleasing and reflect the manufacturer’s identity. The design must take into account proportions, surfaces, finishes, and other aesthetic elements to ensure an attractive appearance. In fact, zinc alloys accept the application of a great variety of finishes, from various galvanic treatments to any type of coatings. The designer, therefore, has a vast range of solutions at his disposal to define the aspect of the product that is most suitable for the target market.

Feasibility

Zinc die casting offers a high level of flexibility in producing complex components; however, it is essential to consider production feasibility from the beginning of the design process. Designers must understand the capabilities and limitations of the zinc die-casting process and design the component to maximize manufacturing efficiency. For this purpose, close collaboration between designers and die casters is essential; the initial co-design activity is, in fact, one of the most critical elements for achieving the product’s productive and commercial success.

Choice of materials

Choosing the right material is crucial to successfully designing zinc alloy products. Zinc offers a unique combination of properties that can enhance product performance and life. Selecting specific zinc alloys for die casting and optimizing them for the needs of the product can significantly influence its success.

Conclusions

Achieving design excellence in zinc die casting requires carefully balancing design and function. A well-thought-out design not only fulfills the product’s functional requirements but also offers attractive aesthetics and efficient production. Investing time and energy in the design of zinc die-cast components can lead to outstanding results in terms of reliability and commercial success. With the proper attention to detail and collaboration with industry experts, it is possible to produce zinc die-cast components that meet both quality standards and aesthetic expectations.

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The circular economy of zinc alloys

The eco-sustainable approach to zinc alloy die casting offers several distinctive benefits. Firstly, the process is based on the efficient use of resources, as zinc is an abundant material on Earth and can be recycled repeatedly without losing its mechanical properties. These characteristics make it possible to reduce the extraction of natural resources and to limit the environmental impact associated with the extraction itself. Furthermore, its ability to be melted down and reused repeatedly without ever losing its mechanical properties makes it an ideal product for the circular economy.

The circular economy is an economic system based on the reduction, reuse, recycling, and restoration of resources. Instead of considering products as objects to be used and discarded, the goal of the circular economy is to create a continuous cycle in which materials and resources retain their value for as long as possible over time.

The properties of zinc alloys obtained by die casting are perfectly suited to the needs of the circular economy since they can be remelted and reused repeatedly, returning to being a raw element ready for new processing. For this reason, it is correct to say that zinc is a material that is reused during its life cycle and not “consumed” as can happen with other materials, which, after each recycling and reuse, tend to lose part of their mechanical properties or chemicals arriving at an “exhaustion” of the material and turning into an unusable waste.

It is also recognized that metal recycling plays a key role in ensuring the availability of resources necessary to maintain and expand the technologies and infrastructure of the future.

The reduced environmental impact of zinc alloys

Zinc die-casting is a much more sustainable process, especially from the point of view of energy consumption, compared to other metal die-casting processes such as aluminum for example. This fact translates into lower greenhouse gas emissions (GHG – Greenhouse Gas) and a reduction in the overall carbon footprint (CF – Carbon Footprint). Furthermore, the die casting of zinc alloys requires less energy to reach the melting temperature than other metals, contributing to further energy savings.

The results of the life cycle assessments (LCA) of zinc alloy die-cast products confirm the low environmental impact. The Life Cycle Assessment (LCA) is, in fact, a methodology used to quantify the ecological effects of a product or service throughout its life cycle: from production to the end of its useful life in which it effectively becomes waste and is no longer usable. This methodology assesses environmental impacts regarding greenhouse gas emissions, energy consumption, water and natural resources use, waste generation, and other environmental factors.

CO2 emissions and other categories that stand in the way of CO2 neutrality. The CO2-neutral concept “avoid – reduce – compensate” can be followed, i.e.:

• Avoid emissions at the outset, both for material extraction and processing.
• Reduce emissions, where possible, during production processes by implementing measures to ensure greater energy efficiency and self-sufficiency.
• Offset the CO2 emitted through projects or certificates that can offset unavoidable emissions.

Conclusion

In conclusion, the eco-sustainable die casting of zinc alloys offers an advanced and responsible approach to production. Thanks to the combination of production efficiency, recyclable materials, and reduced environmental footprint, this technology is aimed at companies that want to achieve environmentally friendly results without compromising functionality. Zinc alloys can replace less sustainable materials by improving energy efficiency and dramatically reducing overall environmental impact.

Furthermore, in our article on the Automation of the die-casting production process, we explore the benefits in economic and, above all, environmental terms of a production process converted from manual to automated. By analyzing a specific case study, you will discover how the die-casting industry is adopting new advanced processes to achieve ever more ambitious quality and environmental sustainability objectives.

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Also this year, the Association of Italian Metalworkers (Associazione Italiana di Metallurgia – AIM) launched its 2020 Aldo Daccò Prize. The award was first established in 1975 to stimulate the sector’s technicians to contribute to the progress of foundry and solidification techniques through essays and original studies. Due to the restrictions in force, the award ceremony was held online on January 18^th, 2020 on the occasion of the opening ceremony of the 38^th AIM national congress.

In the 2020 edition of the Aldo Daccò Prize, Marco was awarded ex-aequo with Engr. Lavinia Tonelli and presented the scientific paper Compensation of Shrinkage Deformation in Zinc Alloy Die-Cast Components.

We interviewed him to learn more about his paper and compliment him on the great result obtained.

Tell us something about the contest you participated in – what is it and why did you decide to compete?

AIM is a non-profit cultural body and was founded in January 1946 with the aim of spreading the science and technology of metallic and other engineering materials. In the wake of its mission, AIM has been organizing this competition for 45 years. I have always followed it for personal interest and I have been looking forward to participating in it for a long time. Having worked at Bruschi Spa for the last few years, I decided to combine my technical knowledge and the experience developed in the field to contribute to the development of the knowledge of foundry and solidification techniques.

What does your paper deal with?

The paper presented is entitled: Compensation of Shrinkage Deformations in Zinc Alloy Die-Cast Components. In particular, it focuses on a specific criticality of zinc alloy die casts, i.e. the occurrence of product deformations caused by the shrinkage of material in the post-molding phase. In the paper I highlighted the difficulties encountered and the possible methods of solving this problem.

Why did you decide to develop precisely this topic?

The problems dealt with in my paper emerged during the inspection of particular products at Bruschi Spa. These problems were first discovered by our Quality Engineer Andrea Salmistraro. During the component analysis phase (performed with a 3D scanner), he noticed that some important dimensions were altered by a defect due to alloy deformation. Thanks to the involvement and contribution of our Strategic Technology Manager Ermo Fusè we hypothesized and subsequently demonstrated that this defect was related to shrinkage caused by Zamak solidification, which varies depending on mass distribution in the component. With my paper I intended to demonstrate that our solution makes it possible to counteract shrinkage deformations of material.

How did you get to the solution?

The first step was to verify that the mold did not have any alterations that could lead to this problem. Once the suitability of molds and sliders was ascertained, we analyzed two practical cases in which the components presented the same problem – despite their clearly different geometric characteristics:

• Flat surface deformation: in this case we started by scanning the deformed piece. Thanks to a CAD software, we extrapolated a lattice and used it to digitally reconstruct the deformed surface and then symmetrize it to obtain a counter-deformed surface. Finally, we applied this surface to the corresponding molding insert surface in order to obtain a piece deformed in the opposite direction and – once cooled – a compliant die cast.
• Cylindrical surface deformation: we followed a procedure similar to the previous one, even if it was not possible to replicate and symmetrize the deformed surface due to geometry complexity. We then scanned the pieces to identify the deformed areas and – after delimiting them with our CAD software – we projected them directly onto the molding insert surface and lastly we counter-deformed them.

Your paper suggests that the deformations addressed are in the order of tenths or even hundreds of a millimeter – how did you guarantee the finish’s precision?

Thanks to his many years of experience and in-depth knowledge of the equipment, our CAM toolmaker and programmer Matteo Annovazzi was able to faithfully replicate the design. He created an accurate CAM program for the milling machine and he then used it to work the molds.

What do you think of this experience and of your victory?

I am very satisfied with the result. I am proud of the existence of entities committed to promoting progress, the exchange of ideas and the sharing of knowledge in this sector. I would also like to thank Bruschi Spa for allowing me to carry out the studies shown in this paper and the support received from the entire team. It is thanks to the collaboration of the various engineers and technicians of the Bruschi team that I was able to demonstrate that it is possible to counteract the deformations caused by material shrinkage by means of a voluntary and targeted counter-deformation of the molding insert surface that generate the surfaces affected by this problem. It is not my victory – it is a team victory.

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