State-of-the-Art Engineered Solutions Through ThixoForming  ThixoForming Technology — A Background
ThixoForming combines the shape making capabilities of plastic injection molding along with conventional die-casting technology. Chipped material is fed through a precisely heated, multi-zone barrel, transformed to a semi-solid state and injected into the mold with vacuum assistance. Once the part solidifies in the mold, it is ejected and trimmed. Because the material is injected under lower temperatures, allowing for laminar material flow, the resulting part has superior qualities over die-casting. Geometries can be more intricate, densities higher, and the finish clean. Ideal for medium to high-volume applications, Thixoforming has advantages relative to processes like die-casting because the metal flows into the die in a smooth way rather than the turbulent flow that occurs when fully liquid metal is injected into a die. Additionally, the ThixoForming process avoids the defects that can occur during turbulent flow, such as when oxide particles get folded into solidifying metal and react with the atmosphere. And because the metal does not have to be fully melted before forming to shape, energy is saved during manufacturing as well. In the article below, John Gaspervich, Vice President of PCC-AFT's ThixoForming Division, describes the company's growing capabilities in ThixoForm manufacturing as it relates to the company's latest challenge — creating a lightweight, intricate optics housing for the military's next-generation assault rifle. Thixomolding Lightens the Load for the Next Generation Assault RifeBy John Gaspervich In regard to its superior dimensional tolerance capabilities, material properties, and ability to create thin-walled, lightweight components, Thixomolding was the clear choice to produce the optics housing for the U.S. military's new Objective Individual Combat Weapon (OICW). The OICW's advanced design gives the soldier a tactical edge with the capability to hit "hidden" targets. This ability lies in a sophisticated "fire control" system and specially designed 20mm air bursting munitions. The advanced sighting system utilizes a laser rangefinder that can accurately measure the distance to the target and program the 20mm projectile to detonate precisely at that distance.  Military Sees the Benefits of Thixomolding
Accuracy of the weapon depends on the sophisticated optics system mounted on top of the rifle. In order to shed weight and cost, the military called on AFT's ThixoForming division to produce the complex structure for the sighting system. Taking a "clean sheet" approach, the optics producer worked very closely with AFT engineers to come up with a design to take full advantage of Thixomolding's thin-wall and high-dimensional precision capabilities. Strength, Weight, Precise Tolerances — Right On Target The Thixomolding design uses pass coring which eliminates the need for secondary machining of complex features that hold critical electro-optical elements. Thixomolding was also able to hold the precision positional tolerances of the various optical bores without the need for additional machining. The average wall thickness of the structure 1.5mm, which allows designers to trim the weight of the part to a scant 170 grams. Furthermore, while the walls are thin, they do not compromise strength since the part is molded in AM60B magnesium allow that provides a high degree of ductility. High Detail and Tolerances with No Sacrifice in Speed Speed of manufacturing is another property inherent to ThixoForming. Cooling time during molding is diminished due to the material's lower temperatures. Along with concurrent design of the part and tooling, this allowed AFT's ThixoForming Division to take the part from concept to first unit delivery in only 12 weeks. John Gaspervich is Vice President of PCC-AFT's ThixoForming Division and can be contacted at JohnGa@pcc-aft.com. | 
