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Die Casting News

Science or Black Art?, Die Casting Lubricants

Posted by Hill and Griffith Company on May 29, 2019 7:20:21 PM

Article for North America Die Casting Association (NADCA) “Die Cast Engineer Magazine” 2007 by Tim Cowell, Technical Director for The Hill and Griffith Company

Introduction

Early on in the Die Cast Industry, die lubricants were usually a concoction of various compounds that the die caster had available to him.

1. He would create different mixtures and whatever yielded the best results for his specific application was what he used. Although much was learned from this trial and error type of evaluation, this method of die lubricant development was considered more of a “Black Art” than a science. Several decades later, there are some who still believe it. Over the years, die lubricant manufacturers and others have gone to great lengths to develop laboratory methods aimed at correlating a product’s performance in the lab with how it will perform in production, and yet there are still no standardized scientific methods within the industry for evaluating die lubricants. The only true test to determine the functionality of a new die lubricant is by its introduction to the production environment.


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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application

The 2017 Die Casting Congress and Tabletop Needs Your Papers!

Posted by Hill and Griffith Company on Mar 22, 2017 4:21:27 PM

(This week's post comes from the March 8, 2017 by NADCA in Industry News. )

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.

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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

Introduction
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. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem

Read the complete article, "Resolving Adhesion Problems in Post Die Casting Operations," here.

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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

Die Casting Video of Fan Blade Manufacturing

Posted by Hill and Griffith Company on Mar 15, 2017 3:03:18 PM

(This week's post is a video that illustrates the typical spray nozzle arrangement for casting fan blades. )

From the die casting video published on Jul 9, 2013, "Die casting is a customized manufacturing method for producing OEM aluminum and zinc parts by forcing molten aluminum and zinc through high pressure into solid steel molds. These steel molds, called dies, are designed to create complicated layouts with a pinpoint accuracy and high volume production. Die cast parts can be precisely shaped, with rough or smooth material sides, and are optimized for a wide variety of attractive and serviceable finishes."

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Die Casting Process Videos

Diluco® 100 Mold Release Products

Posted by Hill and Griffith Company on Mar 8, 2017 1:04:59 PM

Diluco® 100 Mold Release Products for the Diecasting Foundry

Formulated with refined oils, natural and synthetic waxes, vegetable oils, wetting agents and emulsifying agents, they are easily diluted with water and present no known fire hazard. Diluco® 100 products may be compatible with solid particle lubricants and additive packages if conditions of use warrant their needs.

Features:

  • Fast, Easy Release
  • Excellent Thermal Stability
  • Essentially Non Volatile
  • Good Lubricity
  • Provides Good Fill
  • Easily Applied

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent-Mold-Metalcasting-Lubrication

Review of Permanent Mold Metalcasting Lubrication

Posted by Hill and Griffith Company on Mar 1, 2017 3:10:41 PM

(This week's post is a review of an article and video about permanent mold metalcasting lubrication: Permanent Mold Casting from Custompart.net and Permanet Mold Castings video by China Savy.)

Permanent mold casting is a metal casting process that shares similarities to both sand casting and die casting. As in sand casting, molten metal is poured into a mold which is clamped shut until the material cools and solidifies into the desired part shape. However, sand casting uses an expendable mold which is destroyed after each cycle. Permanent mold casting, like die casting, uses a metal mold (die) that is typically made from steel or cast iron and can be reused for several thousand cycles. Because the molten metal is poured into the die and not forcibly injected, permanent mold casting is often referred to as gravity die casting.

Permanent mold casting is typically used for high-volume production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum alloys, magnesium alloys, and copper alloys. However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers, and wheels.

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent-Mold-Metalcasting-Lubrication

Review of Die Cast Plunger Lubrication System Patent

Posted by Hill and Griffith Company on Feb 22, 2017 2:11:49 PM

(This week's post is a review of a die casting plunger lubricant patent US 5076343 A in order to learn more about the application and technology.)

Die cast plunger lubrication system patent

ABSTRACT
A lubrication system for the plunger of a die cast machine is disclosed that does not require a timing mechanism or an additional pressure source for the lubricant. The forward stroke of a lube piston is used to force lubricant out of a lubrication chamber in the plunger through a passageway to the outer surface of the plunger by decreasing the volume of the lubrication chamber. A spring within the plunger's lubrication chamber is used to retract the piston and thereby increase the volume of the lubrication chamber. The relatively low pressure during this retraction stroke allows lubricant to flow from a lubricant tank into the lubrication chamber for distribution during the next forward stroke of the plunger.

 

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Tags: Die Casting, Die Casting Release Agents, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants

Die Casting Lubricants

Posted by Hill and Griffith Company on Feb 16, 2017 9:35:35 AM

Cost Effective, Innovative and Environmentally Sound Non-ferrous Die Casting Products


Die Casting, Squeeze Casting & Permanent Mold Lubricant products that represent the latest in technology and ongoing research in die casting, squeeze casting and permanent mold-release techniques that will enhance your competitiveness. Our Die Casting Lubricants promote cleaner dies while increasing productivity. Custom blended die casting lubricants for your specific application include: Diluco™ 100 Series water-base, 300 Series for squeeze casting, Concote™ low pressure die casting or permanent mold coating and Plunger Lube™ water-based for cleaner and more efficient cooling.

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates, Die Casting Lubricants

Aluminum Characteristics by Alloy

Posted by Hill and Griffith Company on Feb 8, 2017 3:55:50 PM

(Today's post is a review of an article that was published in the Jul/Aug 2016 issue of METALCASTING DESIGN & PURCHASING. You can read the entire article "Aluminum Characteristics by Alloy" here.)

Inside the aluminum family, the various alloys exhibit marked and unique manufacturing characteristics that distinguish themselves. Generally, cast aluminum should be used for applications that require lower weight and structure without necessarily needing high strength at elevated temperatures. To help you choose the best fit, the following breaks down the castability, machinability, finishing tendencies, weldability and corrosion resistance of common alumi­num casting alloys (Table 1).

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates

The Science of Successfully Anodizing Die Castings Substrates

Posted by Hill and Griffith Company on Feb 1, 2017 2:46:46 PM

(Today's post is the Conclusion of an article, "The science of successfully anodizing die castings substrates," which is a review of several questions received by PRODUCTS FINISHING Magazine. It was published by www.aluminumtoday.com. You can download the full article here or use this link.)

Conclusion
There is no ‘trick’ to anodizing complex alloys; there are ways, grounded in scientific reason, to approach challenges. 

 

Fig 5a and 5b: Schematic of the walls of the anodic oxide at the junction of three anodic oxide cells. An entire cell is bracketed with pink dotted lines; the central pore appears gray with repulsive forces represented by a single sphere. The fcc aluminium structure is at the bottom of the schematic with the current bias represented by bold green arrows. The forming tetrahedral structure (5a and 5b) exhibits the primary oxidation reaction at the interface between the fcc and the electrolyte in the pore by the presence of oxygen atoms on the tetrahedral structure.

The schematic on the right (5b) shows non-aluminium ions (copper colored) diffusing from the fcc lattice, through the tetrahedral anodic oxide network, into the central pore where it will be carried into the electrolyte.

Note how the copper atoms ‘pile up’ at the fcc-tetrahedral interface. This is due to the structural/compositional mismatch between the aluminium and the anodic oxide

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates

Griflube Hydraulic Fluids

Posted by Hill and Griffith Company on Jan 25, 2017 2:59:20 PM

Specialty Industrial Lubricants

The Hill and Griffith Company offers Griflube Hydraulic Fluids that are biodegradable, fire-resistant and high-pressure hydraulic fluid under its new GRIFLUBE® line of specialty industrial lubricants engineered for precision hydraulic fluid applications. The new line of products includes the Aquatech FR 200 premium water glycol, the new biodegradable Bio-Syn fire resistant fluid, Gear Oil EP industrial gear lubricants, Premier AW (Anti-Wear) hydraulic and lubricating oils, Premier R&O hydraulic circulating oils and Slide-Way lubricants.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement

 


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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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