Die Casting News
It’s impossible to do effective die casting without proper lubricants. What are the proper lubricants for die casting and what are the different die casting lubricant benefits to consider? Here is some basic information to get you started from the Premier Die Casting Company as a guest blog.
Lubricants and the Die Casting Process
Once you’ve poured the liquid metal into the mold and it has hardened, you need a way to remove the completed part from the die safely and without damaging the part. The release agent we use to make this happen is called die spray or die lubricant. Before each shot, we apply the die spray or lubricant to ease the part removal from the mold. It’s important to use a precise amount of die lubricant — not enough, and the part may stick, leading to defects and shutting down production. Too much, and you may end up with die lubricant that fails to evaporate, leading to porosity inside the casting and poor surface finish of the part.Read More
NADCA Video News Update: Engineering Die Casting Dies: Dimensional Repeatability
The material presented in this video are some highlights from NADCA’s online webinar - Engineering Die Casting Dies: Dimensional Repeatability. This looks at defining what the customer wants and gives a standard approach to what the process can normally achieve, with such things as dimensional tolerances and flatness. It covers defining what your plant can achieve on a day-by-day basis using a small amount of math.
(A transcript from the promotional video excerpt.)
"Things can change that can change dimensions. Cooling time, the time the casting is in the die. The steel die is very, very strong aluminum or zinc, or whatever is not, so the longer you hold it in the die, the more the casting will have the dimensions of the die. There is a limit because if you go too long, the casting will crack, but the closer you want to dimensional tolerance, the longer your cooling time usually is, not always, but usually is. Steel guides are very, very strong.
Metal temperature, as you increase your metal temperature or decrease your metal temperature, the amount of heat going into the die changes, so you are now getting castings that are different in dimensions.
Die temperature across the insert - if you have the left side of your die is hotter than the right side, then the casting coming out will usually be hotter on the left side than on the right. As it starts to cool, the left side has to cool more, so it will shrink more, so the casting will warp. You start to get dimensional changes, difference from left to right. That's why cooling of the die is so important. Internal cooling is critical to controlling dimensional accuracy. We have produced castings with extreme flatness, extreme dimensions, and it all comes down to, or part of it comes down to controlling the die temperature and making it consistent.
Spray time, the days of spraying the die to control die temperature, in many plants, is over. The spray is to add the lubricant and to cool certain sections, which you cannot cool internally. For example, the fins on an air cooled motor. It's very hard because there are a number of cores in there, but most of the time, die spray is down to a minimum. We are consistently using die sprays on 2,500-ton machines where the die spray time is a second or .8 of a second to get accuracy. Die spray pattern, again, the same thing. You change your die spray pattern, you will change your dimensions of your casting.
Pre-heating of dies, if you use a blue flame, a strong gas torch, then you are heating the dies in certain spots. When the aluminum or zinc, or magnesium, or brass starts going into it, it changes the profile, so there is a difference between the first few shots coming out and the last, the shots during production when the die has become stable. People say, "How many die pre-heats should I do?" There are many ways of finding out, measuring die temperature, measuring the quality of the part, measuring the accuracy, but it's worthwhile doing it. There is no magic rule that says make three castings; everything will be fine. It depends on your plant. It depends on how you design your dies.
Die flash, that's an obvious one. You flash the die; you slowly build up metal on the joining faces. The die splits, and then your dimensions across the die are changing. The die flash builds up until it gets to a certain level, and then either an operator removes it, or the die spray blow blows it away. That gives you changing dimensions.
In the modern plant, die flashing is something that is attacked very, very definitely to make sure that it does not happen. There are a number of plants internationally, which do not have die flashing.
Soldering, or soldering, that's where metal sticks to the die. It chemically attacks to the die, so you can have, in one section of the die you get soldering, as the casting's ejected, it sticks on that spot. It's more difficult to eject, so the casting bends. You can get it on cores, and as it slowly builds up, you are losing dimensional accuracy. The diameter is increasing. If you're using coatings, if you're using jet cooling, if you're using a number of things, you can postpone soldering a lot. Very difficult to get rid of it, but you can postpone it coming.
There are many, many other things that can change."
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.
About the North American Die Casting Association
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:
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, die casting 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
Setup, Startup, Warm-up, Shutdown and Safety - Learn to Properly Operate the Die Casting Machine with courses from the North American Die Casting Association.
This year NADCA will be focusing on presenting thier Nation Courses in webinar format. This will allow participants to gain a thorough understanding of the subject matter without the additional cost of travel. There is also the option to attend all courses in a designated Level in order to fulfill certification requirements. NADCA's Operating the Die Casting Machine series is next up on their 2017 course list. Operating the Die Casting Machine is a course detailing the basic die casting setup, startup, warm-up and shutdown.
The material presented in this video are some highlights from NADCA’s online webinar – The Role of Die Casting Lubricants – presented by NADCA’s Beau Glim. Die lubricants are a necessary part of high pressure die casting. The lubricant provides a thin layer to protect the die steel from molten metal. The full presentation discusses what die lubricants are and characteristics important to die casting, how to apply die lubricants in operation, problems caused by improper use of die lubricants, and alternatives to conventional die lubricants.Read More
Regular reviews and benchmarks are important for successful die casting process evaluationsHill and Griffith offers this helpful Die Casting Process Evaluation Form to submit your input.
Here's great video describing both the hot and cold chamber die casting process by Mechanics Tips.
Mercury Marine's new high-pressure die casting machine is now the largest in North America
FOND DU LAC, Wis., April 3, 2017 -- Mercury Marine, the world's leading manufacturer of recreational marine engines held an event today to officially announce commissioning of the largest high-pressure die casting machine in North America. Since 2009, Mercury Marine has now invested more than $800MM in R&D and manufacturing expansion at its Fond du Lac campus.
This specific investment is a 4,500 ton Buhler-Prince machine. Installation began late in 2016 and was just completed in late March 2017.
"This new machine positions us to make castings that no one else in the industry can do," said Mike Meyer, general manager Mercury Castings. "With this new machine, Mercury can make larger, lightweight structural components and reduce the overall weight of our engine by producing more efficient castings."
(Photo from Lake County, Mercury Marine Dealer)
CONCOTE™ permanent mold coatings formulated with special refractories, binders, wetting agents, and preservatives.
CONCOTE™ products provide a thin continuous film between the surface of the die and the castings.
Desired Surface Finish
Good Lubricity and Insulation
Good Release Properties
Prevents Premature Die Failure
Video from FLOW-3D, "Simulation of a low pressure die casting showing the filling temperature of a tire rim using FLOW-3D Cast."
The Die Casting Congress and Tabletop is interested in your paper! Submit a proposal today to the NADCA Paper System!
NADCA would like to urge all metalcasters, researches and suppliers to submit papers on new technologies, procedures, equipment, and other innovations that contribute to productivity and quality enhancement in the metalcasting industry. Especially desired are papers relating practical experience and case studies from casting personnel, and papers on metalcasting management and marketing strategies.
Here's an example of a technical article by Hill and Grifftih's Tim Cowell, Technical Director, published in DIE CASTING ENGINEER, official publication of the North American Die Casting Association
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 an 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.
- What creates Adhesion?
- What prevents Adhesion?
- Assessing the Problem
- Solving the Problem
Tags: Die Casting, Die Casting Release Agents, Die Casting Supplies, Die Casting Release Agent Application, 2017 Die Casting Congress, Die Casting Process Improvement, Die Casting Lubricants, Die Casting Process Videos
Hill and Griffith Customer Service
We're known for our hands-on approach. Let us visit your plant and recommend metalworking fluids that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity.
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.
Technical Services & Support
On-site process surveys, Defect investigations, Product testing, Tooling start-ups and Statistical process controls and much more. Also, lab facilities are available to provide testing upon request.