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.
The material presented in this video are some highlights from the North American Die Casting Association’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.
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.
Shrink porosity can also be reduced by metal pressure.
"With the high pressure die casting process, we use intensification in all of these processes whether it's called the whole time in zinc, whether it's intensification in aluminum and magnesium, we're using those high pressure features to fill those voids.
Define what the customer wants and use a standard approach to what the die casting process can achieve.
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.
The die temperature’s effect on surface defects and the die temperature operating window will be discussed next
A low die temperature affects surface defects by cooling the fluid metal stream and increasing the percent of solidified metal in the metal stream
If the percent of solidified metal is high, then it becomes stiff and solid and does not knit together well; And the flow forms "wrinkles", or cold flow
A cold die can be compensated for by having a shorter fill time - this means a higher plunger speed
In other words, we can exchange plunger speed for die temperature.
Measuring die temperature should be done on every job - most don’t do it enough, but it is required to really minimize surface defects
In general, measuring can be done three ways: – Hand held probe – Thermocouple in the die – Infra red device
Each has advantages and disadvantages: Hand held probe: accurate, but must stop the machine; Thermocouple in die: continuous, but does not measure surface temperature; Infra red: easy, but not as accurate
The material presented in this video are some highlights from NADCA’s online webinar - Engineering Dies: Thermal Design - Why Bother. This covers WHY the thermal design is important. It introduces the simple, but important variables such as surface area and the amount of heat that needs to be controlled. It has been clearly shown that using excess die spray to control die temperature usually results in lower die life, higher variation in quality day-to-day and increases gas porosity. Thermal design is important but can be simple.
High Integrity Die Casting Melting, Melt Treatment, and Transfer
The material presented in this video are some highlights from NADCA’s online webinar - High Integrity Die Casting: Melting, Melt Treatment, and Transfer for High Integrity Die Casting. In this webinar best practices of melting, melt treatment and transfer for aluminum high integrity die casting of structural components will be presented and discussed. Many oxide and other inclusions originate from inappropriate practices with the liquid aluminum before it is cast. They cause quality issues / high scrap rates and reduced properties. This webinar explains how to avoid them by using best practices like filtering, degassing, fluxing, skimming, settling, quiescent transfer, etc.
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.