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Die Casting News

Making "Cents" of Die Casting

Posted by Hill and Griffith Company on Feb 19, 2020 8:00:00 AM

Cost savings, a streamlined production process, and increased quality are only a few of the reasons why die casting is an excellent alternative for manufacturing small gears.

Excerpt from the October 2004 issue of Gear Solutions by Stuart Burke

For many applications, zinc alloy die cast gears provide an opportunity to cut manufacturing costs dramatically and improve part-to-part consistency. The cost of simple spur gears, as well as complex helical and worm gears, can be cut by up to 80 percent. Die casting can enhance rack gear performance by incorporating features unattainable by other manufacturing methods.

Bold statements? Not really. High pressure, hot chamber die casting machines and high precision tooling debunk the myths that many have considered to be the limitations of the die casting process. Extremely tight tolerances can be held over long production runs, and gears are cast net-shape and flash free, ready for use with no secondary finishing operations required. And precision die casting leaves no room for variations. Part to part consistency is inherent in the tooling.

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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, Gear Solutions

Video News Update: Die Casting Lubricants, Applications and Effects

Posted by Hill and Griffith Company on Feb 12, 2020 11:20:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Lubricants, Application and Effects. The application and background of pulse spray is reviewed. Actual Case Studies are reviewed on the application of pulse spray in two die casting facilities. Electrostatic Spray - The basic principles of electrostatic spray are reviewed. The application of electrostatic spray is demonstrated. Plunger Lubrication - The function, chemistry and application of plunger lubricants are reviewed. This webinar also reviews the effect on quality of die cast parts if the plunger application is not closely controlled.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Die Cast Prototyping the Right Way

Posted by Hill and Griffith Company on Feb 5, 2020 8:00:00 AM

Excerpt from the May 2012 issue of Design World by Adam Scichitano and Mike Guilfoyle

What’s the best way to rapid prototype a die cast component? Engineers with some die casting experience may reflexively answer “spin casting” or “machining.” A better answer, however, would be “die casting.”

That’s right. It turns out that the ideal way to prototype a die cast part is actually to die cast it.

While spin casting and machining can produce great-looking prototypes, neither process produces parts whose mechanical properties truly replicate those of a production die casting. The reason why comes down to process-dependent microstructure differences.

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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, Design World

NADCA Publications: Die Casting Process Control

Posted by Hill and Griffith Company on Jan 28, 2020 6:53:56 PM

Chapter 8: Release Materials

Excerpt from the NADCA Publication E-410 by E. A. Herman

When the die has opened and the casting has been ejected, but before the die closes again, the cavity areas of the die receive an application of a release material. The application is usually made by spraying the material as a fine mist. Sometimes the application is not made every time the die is open, but only after some small number of shots. The purpose of the release material is to keep the casting from sticking to the die. The material is called by a variety of names including “lube,” “die spray,” “die lube,” “spray,” “parting” and “release.”

The practical die caster knows that the release material can have a significant influence on the performance of the die casting die. Sometimes, by changing the type or brand of material or by changing the application pattern or quantity, the operating performance of the die is improved. The improvements are not limited to the sticking of the castings to the die. Often surface finish, productivity, porosity or even warpage is affected. The release material and its application is a significant processing variable.


Fig. 8-1. The die designer should supply a water spray diagram like the one shown here for the processing engineer and the operating personnel. The dilution ratio must then be made to get the correct amounts for both water and release material on each area of the die.

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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

Video News Update: Product Design for Die Casting

Posted by Hill and Griffith Company on Jan 15, 2020 8:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Product Design for Die Casting. This initial webinar in the series will provide an introduction and overview of the die casting process.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Die Casting Spray

Posted by Hill and Griffith Company on Dec 18, 2019 3:42:21 PM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Spray. Die spray is essential for applying release agent to the die. It is also used to help control the die temperature and temperature distribution. This course will give an overview of the literature addressing spray. The overview will finish with applications and areas to explore in your own plant to reduce spray use and casting defects. The following topics ware addressed in this course: Die Spray, Flow rate, Spray angle, Time, Die temperature, Effects of die spray and Strategies for improved die spray.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Mechanical Maintenance & Evolution of Die Casting Machines

Posted by Hill and Griffith Company on Nov 13, 2019 4:42:41 PM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Mechanical Maintenance & Evaluation of Die Cast Machines: Die Casting Machine Primary Mechanical Structures. The first in the Mechanical Maintenance & Evaluation of Die Cast Machines series covers topics related to the major mechanical support structures of die casting machines; the machine base, rails, platen supports, wear pads, die carriers, tie bars and bushings.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

NADCA Video: The Role of Die Lubricants in Die Casting

Posted by Hill and Griffith Company on Oct 30, 2019 7:00:00 AM

NADCA Die Casting Video News & Information

The material presented in this video include highlights from NADCA’s online webinar - The Role of Die Lubricants in Die Casting. 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. This presentation will discuss 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.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Advanced Approach to Die Casting Process Control

Posted by Hill and Griffith Company on Oct 23, 2019 7:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Advanced Approach to Die Casting Process Control. In this we define what variables we have control of and what impact this has on the many variables that we can’t directly control. This then covers the die casting measurements that should be taken and the great care in choosing the right variables to measure. This data is then used in two ways, 

  • Historical - what was measured in the past and how can the company gain the best information.
  • Planned Trials - what is available to let the company carry out a multi variable experiment and gain the best advantage for future production.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video-High Integrity Die Casting: The market, Applications and Commercial Aspects

Posted by Hill and Griffith Company on Aug 8, 2019 3:19:45 PM

NADCA Video News & Information

The material presented in this video include highlights from NADCA’s online webinar - High Integrity Die Casting: The Market, Applications and Commercial Aspects of High Integrity Die Casting. In this webinar the rapidly growing market for high integrity die castings is presented and applications in the various market segments are discussed. The main growth sector is automotive, where there are increased car body applications like shock towers. This is not the only market segment where structural high integrity die castings are increasingly used. We can find structural high integrity die castings more in motorcycles, recreational vehicles and also boats.

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

 


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