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Die Casting News

NADCA's Congress West Returns! Spotlights Die Casting Lubricant

Posted by Hill and Griffith Company on Dec 13, 2017 2:01:52 PM

Room Block Closes December 21 - Register Today!

From the Dec 13, 2017 Newsletter: 

NADCA is excited to announce the return of Die Casting Congress West on January 11-12, 2018 at the Hilton Long Beach. The Congress will feature technology highlights of our Congress in Atlanta earlier this fall. The event will kick off with a cocktail reception on January 11 and lead into a full day of presentations on January 12.  Presentations to include: 

Session: State of the Industry
An update on the current state of the die casting industry.
Paul Brancaleon, North American Die Casting Association 

Session: Structural
The ability of the die casting industry to improve cast component performance will help die casting continue to be a relevant manufacturing process. Structural die castings have been identified as having the potential to expand markets for die castings by providing improved mechanical properties. Higher strengths and elongations allow die castings to be used as structural, or even crash-worthy, components on automobiles. Research on alloys and heat treatments used in structural die castings will be presented during this session.
Paul Brancaleon, North American Die Casting Association 
 
Session: Die Coatings  
Die casting is a harsh environment for dies and tooling. Heat checking, soldering and wash-out are all issues that die cast tooling faces. Research is being performed on the use of coatings to not only protect the tooling, but also reduce the amount of die spray needed. Protecting the surface of the die, as well as the shot sleeve inner diameter, will extend the life of the die and sleeve, which in turn leads to better quality castings.
Steve Midson, The Midson Group
 
Session: Computer Modeling
To make higher quality die castings the die casting process needs to be understood on a fundamental level. Transforming the basic principles of die casting into mathematical equations, the process can be simulated on a computer. Advances in computer simulation lead to process improvements, improved tooling, and optimum utilization of new alloys.
Al Miller, The Ohio State University

Session: Advanced Technology    
Customers are constantly looking for higher quality parts at lower costs with shorter lead times. There are limits to the benefits of improving process control. Eventually, new technology is required to meet the demands of new products or stricter quality and functional requirements. This session will look at some of those new technologies and how they can be utilized to improve die castings.  
Beau Glim, North American Die Casting Association

The Congress is sponsored by a limited number of Suppliers that attendees will be able to meet with to learn more about products and services available to the die casting industry.

Sponsors Include: 
Thermtronix Corp
BuhlerPrince Inc
Visi-Trak Worldwide, LLC
Frech USA Inc
B&L Information Systems Inc
Oerlikon Balzers
MAGMA Foundry Technologies Inc
Hill and Griffith Co
Hildreth Manufacturing LLC
Midland Technologies, Inc
Anviloy By Astaras Inc
HPM North America Corporation

The cost is just $20 for NADCA Members and $50 for Non-Members (note that registration includes access to the cocktail hour as well as breakfast and lunch on January 12).  In addition, if you will be sending 5 or more people we are offering special pricing.  

Information and registration can be found herePlease note that the housing block closes December 21, so make your reservations right away! If you have any questions please feel free to contact Melisa Ryzner, CMP at mryzner@diecasting.org or 847.808.3161.


A Short History of the Die Casting Lubricant

Die casting has progressed over the last sixty years from small parts of lower melting metals and alloys such as zinc, to castings of large parts, such as tailgates and engine blocks with high-melting alloys of aluminum or magnesium.

The metals are injected into a mold very quickly and under high pressure. The pressure is maintained until solidification, which produces accurate parts with good surface finish. Depending on the alloys, it's possible to obtain a variety of physical and mechanical properties over a range of sizes and weights.

As die casting conditions grow more severe with higher temperatures, pressure and increased part size. Higher performance die casting lubricants are needed to enhance the process, as long as they don’t negatively affect the quality of the casting.

The Hill and Griffith Company is dedicated to providing high performance die casting lubricants, application and management technologies to continue to increase the size, quality and strength of diecast parts and assemblies.


Die Casting Process in Google News:

The global aluminum casting market is projected to reach USD 97.36 billion by 2025

Die Casting Machine Market 2022 | Industry Outlook, Growth, Trends and Forecast in Europe


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting, Die Casting Tooling Coatings

Application of die casting lubricant

Posted by Hill and Griffith Company on Dec 6, 2017 3:49:04 PM

Proper die casting lubricant and its application ensure that parts eject easily and without defects.

Also called mold release or die spray a precise amount of it is sprayed onto the steel mold before each shot. It evaporates when it comes in contact with the hot steel leaving just the right amount of lubricated coating and required temperature of the mold.

If it cannot evaporate fast enough or if the tool cools too quickly, the molten metal may become more porous. Porosity is always caused by the die casting process. Proper component design, draft, overflows and venting can reduce porosity; as well as specially formulated die release agents.

If there is not enough, the component may stick in the die and cause defects. The larger the draft; the less mold release required. 

Die lubricants are formulated specifically for zinc, aluminum or magnesium and the complexity of the die casting. 

Water-based lubricants provide a release agent and die cooling. Oil-based lubricants may be more appropriate for painted or plated components. It doesn’t provide the same cooling as water-based. Oil-based allows for an increased temperature which may be required for high-quality finishes.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting, Die Casting Tooling Coatings

NADCA News: Die Casting Tooling Coatings & Congress West

Posted by Hill and Griffith Company on Nov 29, 2017 3:20:39 PM

Video News Update: Coatings for Die Castings: Conventional Coating Processes

From the November 29, 2017 Newsletter: 

Video News Update: Coatings for Die Castings: Conventional Coating Processes



The material presented in this video are some highlights from NADCA’s online webinar - Coatings for Die Castings: Conventional Coating Processes - presented by Stephen Midson of The Midson Group. Conventional coatings (nitriding, carbonitriding) have been used for some time on die casting dies. This introductory webinar will review these processes, and describe die failure mechanisms (soldering, erosion) they are used to address.

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting, Die Casting Tooling Coatings

NADCA Video News Update: Die Casting Process Modeling

Posted by Hill and Griffith Company on Nov 22, 2017 12:10:22 PM

The material presented in this video are some highlights from NADCA’s online webinar - Modeling: Die Casting Modeling Capabilities - presented by Charlie Monroe.

From the November 22, 2017 Newsletter

In this course capabilities of die casting process modeling will be reviewed from the current NADCA literature. Common modeling approaches and typical results will be discussed. Topics include: What is simulation, the hows of simulation, and more.

Click here for information.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: www.diecasting.org/store/detail.aspx?id=WEB072

From the highlight:

 "Once you have a project description and a clear objective for that simulation, the next question is always how detailed do I need to get on those geometries that I need to simulate. The statement at the top basically is saying without the "right" geometry, as produced on the shop floor, you can't expect to get comparable results

I have, let's say, an expected geometry on the top line, and then I have three different options for simulation on the bottom. Everyone may laugh and say the geometry representation on the left is not very good, but if all I'm interested in the solidification time, for instance, perhaps that core doesn't really, or that slide doesn't really take up much of the solidification heat, and so my simplified block is sufficient to give me the overall solidification time, so I know how long the duration is. That would be one option.

Then in the middle section, you can see that I've removed all the draft, and I have included a slide in this case. In that case, maybe the draft didn't influence my results. If I'm not interested in the filling, if I'm only interested in where is the hot spot in this part, that geometry in the center may be sufficient to answer the question.

Then, on the right, I have probably the most faithful representation of that geometry, but again, maybe I'm missing the parting line, or this may give me more inclination about what the fill might be, what is the finished section on the part, but it still might be missing some different pieces. Again, even from this perspective, you can see that with particular forms of the geometry, I can answer questions, but certainly, if I had a question of whether the draft is sufficient, the two cases on the left is not going to be able to answer those problems for me. I have to make sure that I've included the right pieces of the geometry, the drafting, the correct holes if those are actually cast in holes or removed. Those are all questions that need to be answered as you're going through your model.
This is just giving some additional examples of things that could happen. I certainly ran across many of these when I was working with Caterpillar.



When we're asked to, for instance, quote a geometry or think about it, knowing which of those features are the machined features and what additional stock might need to be added if it is a machined feature may be a missing part of the geometry. Certainly, missing features or unanticipated features that are in there can be a problem for getting a realistic answer to the simulation.

The incorrect runner system from what happens on the die versus what happens in our 3D modeling is a problem.

Any lack of venting or thermal lines are all examples of ways we need to reconcile our geometries with the simulation.

In the process of talking to at least one simulation company about their service group, and when you contract service with them, what was the biggest problem that they saw with the simulations and the setups that they were getting, they quoted a number that was fairly high, that it was about 80% of all the problems with non-comparable to simulation results came from the wrong geometry or the wrong mesh that they had.

Again, these are not problems generally. I know I never go into a project where I'm intentionally trying to not simulate the right geometry, but then in the process of ... Normally our simulations are run earlier, and then later we go back, and we have an actual process, going back and validating that what happens in the shop practice versus what happens in our simulation world, it's very important to reconcile so that we can diagnose future problems that we'd end up having.

To purchase access to this course, visit the NADCA Marketplace at www.diecasting.org/store. Purchasing a course through the online education system grants you one year of access to the recording, presentation, support material, and test when applicable.


Die Casting Process in Google News:

Die Casting Machine Market with Geographic Segmentation, Statistical Forecast and Competitive Analysis Report to ...

New Report of Die Casting Machine Market Overview ...


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Read More

Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting, Die Casting Process Modeling

Die Casting Release Video of Application by Kawasaki Robotics

Posted by Hill and Griffith Company on Nov 15, 2017 7:19:12 PM

Video shows Kawasaki robots extracting die casting and applying release agent to mold

 

This application shows a Kawasaki F-Series FS45N Robot extracting aluminum parts from a mold. A second Kawasaki F-Series FS10N Robot is utilized to spray mold release agent on the die surfaces. The automated process ensures operators will not be exposed to hazardous emissions or be in harms way of moving machinery.

View die casting release video in YouTube "Mold Extraction with Release Agent Spray - Kawasaki Robotics.Download video link.

"The hot steam and hazardous emissions from die casting machines have been a cause of problems in the aluminum casting process. Kawasaki Robotics offers a viable solution to these serious hazards. First, the Kawasaki FS10N robot sprays the mold with release lubricant prior to start of the casting process. The FS10N robot effectively and completely sprays the entire surface of the casting with release agent. This coating process accurately dispenses a proper amount of release fluid, and the robot ensures that is applied evenly, to only those areas that require lubricant, resulting in a reduction in waste and significant cost savings. 

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting

Process Simulation and Optimizing Die Casting Lubricant Spray Patterns

Posted by Hill and Griffith Company on Nov 8, 2017 12:09:05 PM

Learn the Benefits and Limitations of Die Casting Process Modeling and Simulation, including die casting lubricant spray patterns

This series of three NADCA webinars is a brief overview of issues related to modeling and simulation of the die casting process. Emphasis is placed on making a distinction between modeling and simulation and understanding where simplifications necessary to successfully implement simulation software require special attention by the end user.


Part 1 - Background -

The first of three sessions addressing die casting modeling and simulation issues covers basic background material. The relationships between simulation and modeling is introduced with emphasis on the fact that simulation always requires modeling, but modeling does not necessarily require simulation. The concept of simulation is introduced as the numerical solution of models developed from basic models developed primarily from fundamental conservation laws. Modeling issues discussed include definition of problem boundaries, approximation of geometry, restriction of the phenomena (e.g. thermal, flow, stress, etc.) of interest, and the importance of boundary conditions. The special problems presented by widely varying spatial and temporal analysis scales are also introduced.
Date: November 14, 2017



Part 2 - Selected Technical Details -

The basic equations of physics do not change from one simulation package to another, but the solution procedures may vary. Some of the key differences of finite element, finite volume, and finite difference are briefly illustrated and the pros and cons of each are reviewed. Specialized elements available in many general-purpose CAE packages, but generally not available in casting packages, are also illustrated to help understand why questions need to be asked to fully understand how a casting simulation package is generating certain types of results. Geometry and meshing issues and the impact on the solution are considered. Some of the problems inherent in comparing simulation results with casting results are illustrated including the fact that nearly all such comparisons are qualitative. The session concludes with an overview of typical solution rendering techniques and their pros and cons. 
Date: November 15, 2017


Part 3 - Limitations -

This session is a review of the range of modeling simplifications that are used to make simulation tractable, but then require careful interpretation of the results. Included are time-scale issues and transient versus steady state results including temperature creep; modeling of spray; selection of heat transfer coefficients; technical issues modeling heat loss during fill; cooling line performance, and venting performance. The benefits of special purpose models to provide engineering insight to supplement simulation results in select cases is also illustrated. 
Date: November 16, 2017

Purchase a single webinar
Part 1: Die Casting Process Modeling and Simulation – Background
Part 2: Die Casting Process Modeling and Simulation - Selected Technical Details
Part 3: Die Casting Process Modeling and Simulation – Limitations



Purchase access to the entire webinar series
Die Casting Process Modeling and Simulation Webinar Series

These webinars will take place at 1pm CDT on the dates listed. The cost per webinar is $69 for Corporate Members, $99 for Individual Members or $119 for Non-Corporate Members. Please note that registering for a webinar grants you access to the live broadcast on the given date. No recordings or pdfs of the presentation will be issued.

Headquartered in Arlington Heights, IL, the North American Die Casting Association (NADCA) represents the voice of the die casting industry, representing more than 3,100 individual and some 300 corporate members in the United States, Canada and Mexico. NADCA is committed to promoting industry awareness, domestic growth in the global marketplace and member exposure.


Die Casting Process in Google News:

Aluminum Casting Market Size Worth $97.36 Billion by 2025 | CAGR: 7.8%: Grand View Research, Inc.

Global Brazil Automotive Parts Die-Casting Market Outlook, Growth, Demand, Forecast 2017-2022


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Read More

Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting

Aluminum Die Casting Fan Housing Performance Requirements

Posted by Hill and Griffith Company on Nov 1, 2017 2:28:27 PM

Today's post is a review of a NADCA presentation titled, "A Study in Aluminum Die Casting Housing for a Thermo-Electric Fan." You can find the entire presentation here.

The Requirement

  • In cold climates, military personnel need warm shelter for protection from the elements. In tents, sheds, and buildings without central heating, the shelters use individual space heaters to provide warmth.
  • In such uninsulated structures, the hot air from the heaters rapidly rises to the ceiling without warming the actual living space.
  • The comfort level in these shelters is markedly improved if the warm air is directly circulated throughout the shelter, as compared to natural convection conditions.
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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Lubricant, Die Casting Technical Support, Aluminum Die Casting

 


Hill and Griffith Customer Service

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We are pleased to provide samples in quantities large enough to allow you to "try before you buy." Metalworking fluids, Die casting and squeeze casting lubricants, Casting operations products, Water glycol, Trim press lubricants, Surface protection for casting storage, Corrosion protection for die storage, Cleaners for machines and dies, Corrosion protection for machines, Heat treatment quenchants, and Heat-transfer fluids. Also, Industrial lubricants Griflube®, Hydraulic fluids with fire-resistant and anti-wear properties, Bio-Syn natural ester-based hydraulic fluid, and Way oil knuckle lubes.

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