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Die Casting News

Reduction of Blowholes in Aluminum High Pressure Die Casting Machines

Posted by Hill and Griffith Company on Aug 12, 2020 8:43:40 PM

Excerpt from the August 2018 article from the International Journal of Engineering & Technology by P. Nagasankar, et.al.

Abstract

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defects found through why-why analysis technique. Process capability of current high pressure die cast manufacturing is checked. The current problem of blowhole defects are solved by making an improvement in design of the die inserts. In-gate directions are changed to obtain modified improved flow patterns. Using magma flow simulation software, existing and modified design is compared. It is found that modified design shows superior results, and using this, the defect of blowholes is minimized satisfactory.

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, FOUNDRY Management & Technology, Die Casting Lubricant, Die Casting Process, die casting lubricant management

High Integrity Die Casting Processes

Posted by Hill and Griffith Company on Aug 5, 2020 8:46:06 PM

Defects in High Pressure Die Casting Processes

Excerpt from the instructional book by Edward J. Vinarcik

11.1 Introduction

Casting processes are inherently complex due to the phase transformation from liquid to solid metal, which creates all geometric features as well as material properties. With such an intricate process, many potential defects may result. Potential defects related ot high integriy die casting are presented in this chapter. Defects encountered in conventional die casting will be introduced but will not be discussed in detail, as several texts are available that examine these issues. Defects unique to high integrity die casting processes will be discussed in greater detail.

11.2. Conventional Die Casting Defects

Many potential defects commonly found in conventional die casting can also occur in hight ingegrity die casting. often these defects are avoidable if basic guidelines are followed related to component design, equipment selection, die design, process design, raw material quality, process control, die maintenance, equipment upkeep, and material handling. Conventional die casting defects can be divided into three categories: surface defects, internal defects, and dimensional defects. Each category will be discussed separately below.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, FOUNDRY Management & Technology, Die Casting Lubricant, Die Casting Process, die casting lubricant management

NADCA Webinars: Alloys for High Integrity Die Casting

Posted by Hill and Griffith Company on Jul 29, 2020 1:22:42 PM

The material presented in this video are some highlights from NADCA’s online webinar - High Integrity Die Casting: Alloys for High Integrity Die Casting. In this webinar, all aspects of aluminum high integrity die casting alloys will be covered: from AA numbering, basic metallurgy, the role of alloying each element, impurities and their impact on part quality and properties, all the way to different alloy families and existing alloys currently used or under development, with their advantages and disadvantages, current and potential applications as well as achievable properties (using different heat treatments) with each of them.

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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

Using PVD Coatings to Reduce Diecasting Costs

Posted by Hill and Griffith Company on Jul 22, 2020 12:44:02 PM

Coating can address heat checking, excessive soldering, and erosion, to extend die life, reduce die maintenance, and minimize overall manufacturing costs.

Excerpt from the article in the February 2020 issue of Foundry Management & Technology by David Bell, Viktor Khominich and Steve Midson

Diecasting often is the lowest-cost method to produce castings, especially when large volumes of components are required. However, the reusable steel dies used in diecasting typically are expensive, and may be a significant portion of overall production costs. Therefore, extending die life can have a significant effect on reducing production costs. Dies typically fail for one of three reasons: heat checking, excessive soldering, or erosion, and using PVD coatings to address these mechanisms can extend die life, reduce die maintenance, and so minimize overall manufacturing costs.

Diecasting involves injecting liquid metal into a reusable steel die at extremely high rates (gates speeds between 80-250 ft/sec, cavity fill times of 0.05-0.2 sec) and high pressures (6,000 to 15,000 psi). Due to these aggressive conditions, soldering (sticking) of the castings to the die can be a problem, and to minimize soldering, casters use a water-based organic lubricant (basically a parting agent) sprayed onto the die face before each shot. The lubricant forms a barrier between the casting and the steel die to minimize soldering and sticking.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, FOUNDRY Management & Technology, Die Casting Lubricant, Die Casting Process, die casting lubricant management

Quick Die Change, Quicker Lubricant Changeout

Posted by Hill and Griffith Company on Jul 15, 2020 4:03:21 PM

How Lubrication Strategies Affect Changeover Time

Excerpt from the article in the September 2012 issue of Stamping Journal by Troy Turnbull

To survive, a person’s body relies on getting fluids to the right places at the right time, and the same goes for the stamping process and die lubrication. When should the lube turn on, and for how long? Does the process require flooding, split-second lubrication, or minimal lubrication? The list of variables goes on, and if a technician overlooks any one of them, he may produce rejected parts, damage tools, and cause lost production time.

Stamping requires a system to distribute the die lubricant mixture accurately, thoroughly, and economically with the proper pressure and volume to supply fluid consistently to each spray nozzle. Stampers must ensure nozzles are positioned properly and the lubricant mixture mixed correctly, with proportions tailored for the application. Finally, stampers can find ways to optimize changeover to reduce setup time and, just as important, the possibility for press setup error.

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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, Stamping Journal

NADCA Webinars: Inclusions, Leakers, and Cracks

Posted by Hill and Griffith Company on May 20, 2020 2:16:57 PM

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Defects - Inclusions, Leakers and Cracks. This course discusses various types of inclusions and corrective measures to minimize inclusions. In addition, causes of leakers and corrective measures are presented. Lastly, the various causes of cracks in die castings are discussed.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: http://www.diecasting.org/store/detail.aspx?id=WEB297

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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

Die Lubrication: The Big Picture

Posted by Hill and Griffith Company on May 13, 2020 11:57:39 AM

Excerpt from the article in the June 2005 issue of The Fabricator by Steven Rainwater

The activities, costs, and results of die lubrication do not neatly occupy related columns on a spreadsheet. When maintenance employees are deciding the best way to replenish fluid reservoirs, they usually do not review the previous quarter's shipping costs. When die designers select a tool steel, they usually do not focus on whether the fluid actuation is integrated with the press controls. When engineers determine a fluid viscosity, they seldom consider how many bundles of rags the press operators use each quarter. These seemingly unrelated categories and many others are related by die lubrication decisions.

Perhaps no other process in a stamping, forming, or fabricating facility reaches as broadly into the operation as die lubrication does. Yet, because it must be adapted to each manufactured part, lubrication sometimes is the last thing planned, and frequently it is approached haphazardly.

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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, The Fabricator

NADCA Webinars: Shrink Porosity

Posted by Hill and Griffith Company on May 6, 2020 6:17:34 PM

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Defects - Shrinkage Porosity. This course describes how to identify shrinkage porosity, discusses the causes, and provides corrective measures to minimize shrinkage porosity.

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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

Factors That Contribute to Extending Die Life - NADCA Webinar Series

Posted by Hill and Griffith Company on Apr 29, 2020 3:57:18 PM

Failure of dies is typically caused by thermal fatigue cracking or gross cracking. Other modes of failure include soldering to the die surface, erosion and corrosion of the die surface. It is clear that many factors can impact die life, including steel composition, heat treatment conditions, fabrication techniques and die casting processing parameters. The approach used in this 6-part webinar series is to summarize recent research published by NADCA on extending die life.

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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

Methods and Measures to Reduce the Solder Defect of Die Casting Surfaces

Posted by Hill and Griffith Company on Apr 22, 2020 9:15:15 PM

Excerpt from the January 2020 Issue of Global Casting Magazine

The solder defect in die casting affects surface quality and strength, especially in castings with a high seal requirement. The defect could lead to leakage that would mean more wasted cost (Fig 1.). Four aspects of soldering were analyzed, including:

  • chemical principle
  • mold structure
  • release agent
  • die casting process

For example, JAC die casting company in Suzhou, China, supplies parts to customers that don’t allow solder to be visible to the naked eye. For a German company in Shandong, China, which produces automobile parts, the solder defect area can be no more than 20 x 20 mm. Another company which produces parts with thin walls and high temperature pouring, have found it is at higher risk for solder defects.

What factors cause the solder defect? What’s the physical or chemical change between the liquid aluminum and hot iron mold? This article will share the results of a study on this defect based on the chemical principle, mold structure, release agent and die casting process.

Interfacial reaction is a series of chemical interactions that occur between the interface of two phases, according to chemical type, content, status and properties.

Solder defect is started by the chemical and physic reaction due to the strong affinity in Fe-Al. A new compound is created when the mold and liquid Al connect closely. The higher the temperature, the more intense the thermal vibration of the atoms, causing the solder ratio to rise and the corrosion of the mold to increase, until finally, it causes the solder area. When polished, the surface containing a thin nitride layer will be destroyed, causing worse cycle. Some data in the study showed that the affinity of Fe-Al will become more serious as the Fe element is decreased, creating more solder.

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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, Global Casting Magazine

 


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