Connections in metal casting production facilities.

Harting’s Han® High Temp connectors are being used in metal die-casting production systems to minimise adverse environmental effects and reduce maintenance and service periods, line downtime and hence operating costs.

Metal casting manufacturers are continually looking at ways to reduce environmental damaging emissions from their production process to satisfy increasingly more stringent environmental regulations and minimise resultant air pollutants.

For example, in order to produce metal cast automotive engine component parts, sand is typically used with a mixture of organic binders as an important constituent part of the casting process. During this high-temperature process these organic binders can lead to the release of hazardous levels of air pollutants.

To reduce the level of these pollutants there has been a move in the industry to apply certain types of inorganic binder materials mixed with sand. Such a change also requires slight modification to the die-cast tooling and the applied processes. This has involved adjustment to the applied electrical heating processes to the tools. As a direct consequence, higher temperature levels are reached which have a detrimental impact on the life of such tools based on the limited operating temperature range of the electrical interface connections.

Using Harting’s new Han® range of high-temperature connectors can help to reduce this negative impact condition and maximise the lifetime of the electrically heated metal sand casting tools. This, in turn, supports the trend to a significant reduction in the environmental impact of the metal die casting production process. As such, it reduces potential tooling maintenance and service periods, line downtime and hence operating costs.

New sealing materials
For example, bulkhead-side connector seals must not melt or adhere to other integrated component parts over the full operating temperature range. Consequently, Harting has opted for a non-stick coated high-temperature-resistant rubber version, which avoids bonding between the hood and housing even if they are left mated for a number of years.

Many of the hood and housing coatings and lacquers available on the market are not suitable for long-term use at high temperatures as they can cause melting, which can in turn lead to mated parts sticking together. Thanks to the application of a special surface treatment of the aluminium die-cast hoods and housings, Harting has been able to dispense with any potentially detrimental additional protective coating finish.

The insulating body and contacts must withstand both the high ambient conditions of the location and the additional heat generated inside the housing when under mated load. Harting has selected high-temperature-resistant copper alloy contacts that maintain constant electrical properties when heated. In addition, high-temperature LCP plastic insulators ensure long service life.

As a result of the above-mentioned features, Harting’s Han® High Temp connectors are able to permanently withstand operating ambient conditions of +200°C, providing extended operating lifetimes and ensuring reduced line downtime compared to alternative solutions.

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