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Die Casting News

Making "Cents" of Die Casting

Posted by Hill and Griffith Company on Feb 19, 2020 8:00:00 AM

Cost savings, a streamlined production process, and increased quality are only a few of the reasons why die casting is an excellent alternative for manufacturing small gears.

Excerpt from the October 2004 issue of Gear Solutions by Stuart Burke

For many applications, zinc alloy die cast gears provide an opportunity to cut manufacturing costs dramatically and improve part-to-part consistency. The cost of simple spur gears, as well as complex helical and worm gears, can be cut by up to 80 percent. Die casting can enhance rack gear performance by incorporating features unattainable by other manufacturing methods.

Bold statements? Not really. High pressure, hot chamber die casting machines and high precision tooling debunk the myths that many have considered to be the limitations of the die casting process. Extremely tight tolerances can be held over long production runs, and gears are cast net-shape and flash free, ready for use with no secondary finishing operations required. And precision die casting leaves no room for variations. Part to part consistency is inherent in the tooling.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Gear Solutions

Video News Update: Die Casting Lubricants, Applications and Effects

Posted by Hill and Griffith Company on Feb 12, 2020 11:20:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Lubricants, Application and Effects. The application and background of pulse spray is reviewed. Actual Case Studies are reviewed on the application of pulse spray in two die casting facilities. Electrostatic Spray - The basic principles of electrostatic spray are reviewed. The application of electrostatic spray is demonstrated. Plunger Lubrication - The function, chemistry and application of plunger lubricants are reviewed. This webinar also reviews the effect on quality of die cast parts if the plunger application is not closely controlled.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Die Cast Prototyping the Right Way

Posted by Hill and Griffith Company on Feb 5, 2020 8:00:00 AM

Excerpt from the May 2012 issue of Design World by Adam Scichitano and Mike Guilfoyle

What’s the best way to rapid prototype a die cast component? Engineers with some die casting experience may reflexively answer “spin casting” or “machining.” A better answer, however, would be “die casting.”

That’s right. It turns out that the ideal way to prototype a die cast part is actually to die cast it.

While spin casting and machining can produce great-looking prototypes, neither process produces parts whose mechanical properties truly replicate those of a production die casting. The reason why comes down to process-dependent microstructure differences.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Design World

NADCA Publications: Die Casting Process Control

Posted by Hill and Griffith Company on Jan 28, 2020 6:53:56 PM

Chapter 8: Release Materials

Excerpt from the NADCA Publication E-410 by E. A. Herman

When the die has opened and the casting has been ejected, but before the die closes again, the cavity areas of the die receive an application of a release material. The application is usually made by spraying the material as a fine mist. Sometimes the application is not made every time the die is open, but only after some small number of shots. The purpose of the release material is to keep the casting from sticking to the die. The material is called by a variety of names including “lube,” “die spray,” “die lube,” “spray,” “parting” and “release.”

The practical die caster knows that the release material can have a significant influence on the performance of the die casting die. Sometimes, by changing the type or brand of material or by changing the application pattern or quantity, the operating performance of the die is improved. The improvements are not limited to the sticking of the castings to the die. Often surface finish, productivity, porosity or even warpage is affected. The release material and its application is a significant processing variable.


Fig. 8-1. The die designer should supply a water spray diagram like the one shown here for the processing engineer and the operating personnel. The dilution ratio must then be made to get the correct amounts for both water and release material on each area of the die.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, NADCA Education

Choosing Between Permanent Mold and Die Casting

Posted by Hill and Griffith Company on Jan 22, 2020 8:00:00 AM

The metal molds used in die casting and permanent mold casting help drive cost, material choice and casting soundness, but each process offers unique advantages.

Excerpt from the November 2014 issue of Casting Source

The permanent mold and die casting processes share a common ground. While the molds used in sand molding, investment casting and lost foam casting are expendable, metal die casting and permanent molds are used repeatedly. The material and manufacture of the metal molds make initial tooling costs more expensive than the other processes, but if the volume of production is high enough, this cost difference can be overcome. Permanent mold and some types of die casting also offer superior mechanical properties because the metal mold acts as a chill.

Despite the similarities, each process may better suit a particular application, depending on the property requirements, casting size, production rate and design complexity.

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Tags: Die Casting, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Casting Source Magazine

Video News Update: Product Design for Die Casting

Posted by Hill and Griffith Company on Jan 15, 2020 8:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Product Design for Die Casting. This initial webinar in the series will provide an introduction and overview of the die casting process.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Where Die Casting Makes "Cents"

Posted by Hill and Griffith Company on Jan 8, 2020 8:00:00 AM

Sometimes whole assemblies can be combined into a less-expensive die-cast part.

Excerpt from the April 2003 issue of Machine Design

Gating through the center bore of this horizontal gear drive ensures uniform alloy distribution for consistent fill of the thread and gear tooth forms. The walls of the center hole are held parallel within +/-0.0005 in. The drive gear, used in an automobile seat, is cast ready to use with no finishing or deburring operations required.

Designers of a new automotive seat were in a quandary over the most economical way to build the seat's geometrically complicated, horizontal gear drive. It was proving tough to find a process that met the gear drive's precise tolerancing requirements and do so on a budget. The gear drive incorporated not only an Acme screw thread at one end of a bearing journal but also a cross-axis helical gear on the other.

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Tags: Die Casting, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Machine Design Magazine

Quality Stabilization in Aluminum Die Castings

Posted by Hill and Griffith Company on Dec 25, 2019 8:00:00 AM

A Series of Test Shows the Impact of Carbon-Based Coatings in Aluminum Diecasting Operations.

Die castings produced with as-cast or nearly as-cast surfaces are becoming more common, where near-surface layers of the castings are machined. As a result, various problems related to the boundary between chill layers and general internal structures are more apparent. Controlling heat insulation during molten metal infusion, heat transfer during pressurization and thermal diffusion to the mold are critical to diecasting quality. Proper control of these variables will lead to dense cast structures free of chill boundaries.

In the paper “Key Issues for Quality Stabilization of Aluminum Die Castings,” Yuichi Furukawa, Toyota Motor Corp., Toyota, Japan, and Yoshiki Tsunekawa, Toyota Technical Institute, Nagoya, Japan, investigated aluminum diecasting processes. The report includes the results of a durability test of various carbon-based coatings, the effects on solidification structure and a coating’s ability to stabilize diecasting quality.


The typical microstructures of a diecast oil control valve (a) without carbon-fullerene coating and (b) with carbon-fullerene coating are shown.

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Modern Casting Magazine

Video News Update: Die Casting Spray

Posted by Hill and Griffith Company on Dec 18, 2019 3:42:21 PM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Spray. Die spray is essential for applying release agent to the die. It is also used to help control the die temperature and temperature distribution. This course will give an overview of the literature addressing spray. The overview will finish with applications and areas to explore in your own plant to reduce spray use and casting defects. The following topics ware addressed in this course: Die Spray, Flow rate, Spray angle, Time, Die temperature, Effects of die spray and Strategies for improved die spray.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

NADCA Die Casting Congress Awards 2019 - Magnesium Winner Over .5 Lbs.

Posted by Hill and Griffith Company on Dec 4, 2019 11:49:12 AM

For the last 45 years, NADCA has sponsored its International Die Casting Design Competition to showcase outstanding die cast designs while acknowledging the continuous contribution die casters provide to the manufacturing industry. As die castings become more complex, higher quality, lower cost, and more unique, it becomes important for die casters to be involved in the process early in the product’s design phase. A die casting is not a machined part, sand casting, or an extrusion. It is critical for die casters to effectively communicate to the designer requirements to make a quality casting. The winners of the 2019 International Die Casting Competition have exhibited a close relationship with their customer to produce castings that have a complex design, high quality, and ingenuity. These castings often expand the market for die casting and reduce the cost of the part compared to the previous manufacturing method.

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, NADCA

 


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