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Die Casting News

Post Die Casting Operations - Resolving Adhesion Problems

Posted by Hill and Griffith Company on Nov 15, 2018 3:32:25 PM

Introduction

In the Die Casting Industry, many of the castings manufactured undergo secondary operations incorporating the use of paints, adhesives and other polymers such as RTV (Room Temperature Vulcanization).  The application of these types of materials requires the polymer to bond to the metal substrate (surface) of the casting.  When this bond fails, it is considered to be a die casting adhesion problem. For the die caster, this can be a very costly problem; therefore, it is imperative that it be solved quickly.

To gain a better understanding of the problem and its potential solution, the following points will be discussed. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem
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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Is 2017 The Year for 5S - Die Casting Process Improvement?

Posted by Hill and Griffith Company on Dec 28, 2016 9:59:21 AM

Thanks to the North American Die Casting Association for giving us a possible Die Casting Process Improvement New Year's Resolution.

1. Sort: Remove all unnecessary items
2. Set in Order: Arrange items too be used
3. Shine: Clean workplace. Floors, trash, machine, etc.
4. Standardize: Simplify job and content.
5. Sustain: Maintain 5S habit

And some like to add a sixth
6.Safety: Keep Safety in mind during all these steps.


 

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting, Die Casting Process Improvement, Die Casting Congress West

NADCA Die Casting Congress West

Posted by Hill and Griffith Company on Dec 15, 2016 5:15:25 PM

NADCA is excited to announce the first ever Die Casting Congress West on January 18-19, 2017 at the Hilton Long Beach.  The Congress will feature technology highlights of our Congress in Columbus earlier this fall. The event will kick off with a cocktail reception on January 18 and lead into a full day of presentations on January 19.  

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting, Die Casting Congress West

NADCA Structural Die Casting Webinar Series

Posted by Hill and Griffith Company on Dec 7, 2016 1:48:18 PM

Complimentary NADCA Webinar Series
Register: http://www.diecastingdesign.org/webinar

This webinar series is designed to inform the OEM about the benefits and capabilities of structural diecastings and their applications. This new and growing segment of the high pressure die casting industry provides die cast components for critical applications since they are high in ductility, and are also weldable and heat treatable due to extremely low porosity levels. Steve Udvardy, North American Die Casting Association - http://www.diecasting.org - Director of Research, Education & Technology will be presenting a three part webinar series.

(Illustration of the typical die casting machine and consumables provided by the Hill and Grifftih Company.)

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting

Die Casting Release and Plunger Lube Application to Reduce Porosity

Posted by Hill and Griffith Company on Nov 30, 2016 3:52:22 PM

th(This week's post is the combination of a review of the technical paper "Analyze of the Possible Causes of Porosity Type Defects in Aluminum High-pressure Diecast Parts" by Ferencz Peti and Lucian Grama; and 3D scanned images of die casting porosity from Exact Metrology thanks to Amy Cupp.)

Abstract

The most common defect that appears in castings is the porosity type of defect, which can be gas porosity, shrinkage porosity or leaker.

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Resolving Adhesion Problems in Post Die Casting Operations

Posted by Hill and Griffith Company on Nov 17, 2016 4:51:02 PM

Tim Cowell, Technical Director, The Hill and Griffith Company
Published in the Sept. 2014 issue of DIE CASTING ENGINEER, official publication of the North American Die Casting Association

Introduction

In the Die Casting Industry, many of the castings manufactured undergo secondary operations incorporating the use of paints, adhesives and other polymers such as RTV (Room Temperature Vulcanization).  The application of these types of materials requires the polymer to bond to the metal substrate (surface) of the casting.  When this bond fails, it is considered to be a die casting adhesion problem. For the die caster, this can be a very costly problem; therefore, it is imperative that it be solved quickly.

To gain a better understanding of the problem and its potential solution, the following points will be discussed. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem
Read More

Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Magnesium Die Cast Liftgate Cuts Weight, Adds Value

Posted by Hill and Griffith Company on Nov 9, 2016 8:48:49 AM

Meridian Lightweight Technologies and Fiat Chrysler Automobiles teamed up on this year's award winning casting - this first high volume application of the structural magnesium die casting. 

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Tags: Die Casting, Metal Casting, Die Casting Awards, Magnesium Die Casting

Die Casting Lubricants: Science or Black Art?

Posted by Hill and Griffith Company on Oct 27, 2016 9:25:36 AM

  • Article for North America Die Casting Association (NADCA) “Die Cast Engineer Magazine” 2007 by Tim Cowell, Technical Director for The Hill and Griffith Company

    Introduction

    Early on in the Die Cast Industry, die lubricants were usually a concoction of various compounds that the die caster had available to him.

    1. He would create different mixtures and whatever yielded the best results for his specific application was what he used. Although much was learned from this trial and error type of evaluation, this method of die lubricant development was considered more of a “Black Art” than a science. Several decades later, there are some who still believe it. Over the years, die lubricant manufacturers and others have gone to great lengths to develop laboratory methods aimed at correlating a product’s performance in the lab with how it will perform in production, and yet there are still no standardized scientific methods within the industry for evaluating die lubricants. The only true test to determine the functionality of a new die lubricant is by its introduction to the production environment.

    2. Even then, there are issues that are not clearly explainable. For instance, it is not uncommon for a trial die lubricant to work well on one casting and yet create problems on a similar casting running on the machine next to it. This causes many to ask the inevitable question,” Why?” There are no simple answers to this question. In spite of the fact that die lubricant manufacturers know more now about the physical and chemical properties of their products and their potential performance in the die casting environment, there are still intangibles within the die casting process that are often overlooked during product selection. Some of these intangibles are variations in types of castings, cycle times, die design, water quality, machine equipment etc……  Because each of these variables has an effect on the thermal balance of the process, they impact the performance of the die lubricant, which in turn impacts the quality of the casting, the scrap rate, downtime and finally the profitability of the company. The purpose of this paper is to look at areas where the die caster and die lubricant manufacturer can work together to improve the development and functionality of a die lubricant specific to their process, resulting in a superior casting, reduced scrap and downtime, and ultimately increasing the bottom line. There are four areas that need to be focused on: 

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application, Die Casting Awards

2016 Die Casting Award Competition Winners

Posted by Hill and Griffith Company on Oct 19, 2016 5:37:19 PM

We exhibited at the Die Casting Congress and Tabletop event in Columbus on September 26 and photographed the display of die casting award winners. Congratulations!

From the North American Die Casting Association site.

PURPOSE: Promote increased use of die castings by recognizing and publicizing outstanding designs.

ELIGIBILITY: Entries will be judged in several categories of: Aluminum, Zinc and Magnesium die casting. In addition, we will be accepting castings from other alloy families as well! Both custom and captive casters are eligible.

AWARDS: One winning casting will be awarded per category. An award will be presented to the casting supplier and the customer.

JUDGING: There are four equally weighed criteria: ingenuity of casting/product design; overall quality; cost savings & contribution to expanding the market for castings. A panel of independent judges, acknowledged experts, with no ties to eligible casters, will choose the winners. The judges’ decisions are final.


Zinc Die Casting Over 6 oz
Bruschi s.p.a, Via Mendosio, 26, Abbiategrasso, Milan, Italy

Caster Award Nominees - Erminio Fuse
Customer - ARCA Technologies
Function of Part
Frame for PCB and scanner installed in a "Teller Cash Recycler."
Previous Process to Produce Part
Several stainless steel parts welded, assembled with screws, welded and machined.
Advantages Gained
Zinc die casting has eliminated the assembly of the steel frames, now only 2 die cast parts. parts are now cast to near finished condition, removing CNC machining operations (only need tapping ater shot blasting). Increased stiffness of the part provides improved performance of the scanner. Overall cost reduction of 40%.
Part - Mobile Frame
Material - Zamak 5
Weight - 10.25 oz
End Market - Office Equipment

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application, Die Casting Awards

 


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