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.Read More
Die Casting News
Excerpt from the August 2015 issue of Foundry Management & Technology by Pascal Côté, Giovanni Pucella, and Steve Midson
The Swirled Enthalpy Equilibration Device (SEED) represents a new possibility for high-volume, high-productivity, thin-walled casting production. Production process advantages:
- Minimal residual porosity
- Increased die-filling speed
- Extended tool life
- Minimal turbulence
Semi-solid metalcasting (SSM) was developed in the 1970s and became a commercial process for thixocasting (billet re-heating) in the 1990s, and for rheocasting (generating the semi-solid slurry directly from the liquid) in the 2000s. However, despite significant technical and economic advantages, as pointed out recently by Jorstad(1), SSM has never advanced to become the major metalcasting process anticipated by so many early investigators. Certainly, there have been a number of obstacles to the commercialization of SSM, such as the original thixocasting process being relatively expensive, early rheocasting processes not being fully competitive, along with improvements made to already-facilitated competing casting processes (squeeze casting, conventional die casting, and high vacuum die casting.)Read More
Within the die casting process, where molten metal is injected into a steel die, a release/lubricant agent is applied to the die to allow for proper release. These release agents are often referred to as die lubricants.Read More
Mercury Marine officially opened the 23,500 square foot expansion to its diecasting facility.
Mercury Marine officially opened the 23,500 square foot expansion to its diecasting facility. The $9M investment provides needed space for capacity increases, allowing the company to make complex blocks, driveshafts, and gear cases for Mercury’s outboards.
The North American Die Casting Association Offers a self-paced education through their online education system.
GRIFLUBE® Bio-Syn will readily biodegrade as defined by OECD 301 C; and will easily exceed the 60% minimum biodegradability standard, converting CH3-CH2 molecular groups to CO2 within a maximum of 7 days, which exceeds the biodegradability rate of any polyether or polyol ester type fluid.
Hill and Griffith is pleased to submit the following technical information on our Factory Mutual approved fire resistant GRIFLUBE® Bio-Syn hydraulic fluid, as the proactive chemistry of choice for high production foundries, steel mills, casting operations, refineries, and any application which might be predisposed to elevated temperature extremes and have the potential for fire. GRIFLUBE® Bio-Syn was researched and designed as a superior biodegradable fire resistant hydraulic fluid, in comparison to conventional polyol esters, PAG/polyethers, and especially phosphate esters; to offer greater latitude relative to toxicological and environmental compliance, enhanced fire resistance, and maximum lubrication value, for extended wear characteristics in vane and axial piston pumps.
Controlling the temperature of a die casting die through the location of cooling lines is critical to performance and die life.
A properly designed system of water and/or oil lines will process heat energy so the die can be operated productively with the highest part quality possible. NADCA has created a three level approach to addressing thermal control. This series is broken down by beginner, intermediate and advanced courses suitable for people with varying levels of knowledge in this area.
An Outstanding Achievement award was on display at CastExpo 2019 for this T1XX side door mirror, reinforcement bracket.
It was made by Magna Cosma Casting Michigan, Battle Creek, Michigan. The material is aluminum alloy, 5S-F temper. The process is high-pressure, vacuum die casting. The weight is 1.31 pounds. The dimensions are 14.5 inches by 6.4 inches by 15.4 inches. The application is for attachment points and load carrying for truck side door mirror. The customer is General Motors.
Known for its ability to achieve tight tolerances, superior surface finishes and high mechanical properties, permanent mold is a quality option for many applications.
Fig. 1. This aluminum transmission main housing was cast via semi-permanent mold using 27 sand cores.
Unlike sand and plaster molding processes, where the mold is recycled after every part, the molds used in permanent mold casting can be used to produce thousands of components before they have to be repaired. The permanent mold casting process is known for its ability to achieve tight tolerances, superior surface finishes and high mechanical properties. Its ability to achieve these details is based on the fundamental principle of this process—the pouring of molten metal into reusable metal molds.
It is important to know what type of control method is applicable to each of the die casting machine/die/process systems.
North American Diecasting Association (NADCA) has created a three level approach to addressing process control. This series is broken down by beginner, intermediate and advanced courses suitable for people with varying levels of knowledge in this area. Learn more at this NADCA page.
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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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.