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Die Casting News

Using PVD Coatings to Reduce Die Casting Costs

Posted by Hill and Griffith Company on Jan 13, 2021 4:49:57 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 Foundry Management & Technology February 2020 article by David Bell, Viktor Khominich, and Steve Midson.

Die casting often is the lowest-cost method to produce castings, especially when large volumes of components are required. However, the reusable steel dies used in die casting 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. Using PVD coatings to address these mechanisms can extend die life, reduce die maintenance, and so minimize overall manufacturing costs.

Die casting 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, High Pressure Die Casting, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Foundry Management & Technology magazine

Combining Toughness, Thermal Resistance in HPDC Die Steel

Posted by Hill and Griffith Company on Jan 7, 2021 10:32:01 AM

New automotive casting objectives highlight the deficiencies in standard tooling materials, but an alternative promises quality, lower cost, longer tool life, and more

Excerpt from the Foundry Management & Technology November 2019 article

The difficulties of casting high-volume automotive parts are well established, and those issues become more critical in production of critically engineered parts, such as the increasing volume of parts produced by high-pressure die casting (HPDC.) Three experts in hot-work production addressed the issues recently in a white paper for Uddeholm AB's newly developed Uddeholm Dievar 25 Joules tool steel for die manufacturing. It gives "the perfect balance between toughness and heat-checking" for HPDC, and other applications, they claim.

Most dies used by foundries, diecasters, and OEMs are formed in AISI H13 or H11, but the Uddeholm experts raise the concern that the die-related problems of HPDC powertrain and transmission castings have not changed in decades, and may be more acute with the advent of production for hybrid and electric vehicle castings.

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Tags: Die Casting, Die Casting Release Agents, High Pressure Die Casting, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Die Casting Engineer

The Exclusion of Inclusions in High-Pressure Die Casting

Posted by Hill and Griffith Company on Dec 30, 2020 9:07:08 AM

Identifying the Causes and Determining the Solutions

Excerpt from the Die Casting Engineer January 2008 article by Dr. David V. Neff

Defective castings, scrap... Yikes! — The scourge of the high pressure die caster trying to make a good living in a highly competitive marketplace! What's a body to do? Well, for one thing, he can try to avoid making defective castings in the first place! But just what is a "defective" casting? For this article, we wish to consider a defective casting as one which has a defect, right? But there are many ways that a casting can be "defective." For our purposes, we shall limit this discussion to those defective castings where the cause can be attributed to "inclusion" defects — out of the many other defects and their causes that possibly could exist. Inclusions in castings are foreign bodies that exist in the finished casting and are detrimental to the casting's properties and functionality. Where do they come from? If they are present, how do we get rid of them? More importantly, how can we avoid the "inclusion of the inclusion" into the casting in the first place? So, let's start at the beginning.

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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, Die Casting Engineer

High-Pressure Die Casting

Posted by Hill and Griffith Company on Dec 23, 2020 11:30:06 AM

Excerpt from the May 2020 article from the Engineering.com article by Dr. Jody Muelaner

A key process for close-to-market manufacturing of high-value products.

Products are getting more complex, with organic shapes increasingly being specified to achieve the required strength while minimizing material use. There is also a trend for re-shoring and producing goods closer to the market where they are sold. The usual business case for close-to-market manufacturing is being able to respond quickly to increasingly dynamic markets. Reducing the carbon footprint involved in transporting goods and making supply chains more resilient are also important drivers. The current need for an urgent ramp-up in ventilator production has sharply brought into focus the need to respond rapidly to increasing demand with a resilient supply chain. Additive manufacturing (AM) plays into both trends. It is making people believe that products can be any shape we like and that they can be locally produced. In reality, AM has little scope to replace conventional production in the foreseeable future. Issues with material properties, feedstock costs, machine costs and build speeds mean that AM will remain a relatively niche process.

This article gives a detailed overview of another highly automated manufacturing process that can produce complex shapes in high-strength alloys. Die-casting may not be a new technology, but it is very well-suited to many modern products. I recently reported on how European bicycle manufacturers are re-shoring production as demand for high-quality e-bikes ramps up rapidly. These are sophisticated machines that use aerospace-grade materials with correspondingly high prices. In that article, I noted the importance of automation when re-shoring production into high-wage economies and identified high-pressure die casting as the most highly-automated process for high-quality bicycle frames. High-pressure die casting is a highly automated process that can economically produce parts with very complex shapes. It is typically suited to high-volume production. This article explores the process in detail, looking at tooling requirements, breakeven volumes, material properties and surface finish.

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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 Webinars: Defects in Die Casting

Posted by Hill and Griffith Company on Dec 9, 2020 8:59:25 PM

The material presented in this video are some highlights from NADCA’s online webinar - Defects in Die Casting: Surface Defects and Other Problems. This second course covers defects caused by such things as venting problems, surface defects such as “white surface” and die spray marking. It then goes into the two main types of cracking, leakers, flash and flaking/spalling during machining.

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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

Find Out How Spray and Lubricant Affect Die Casting Quality

Posted by Hill and Griffith Company on Nov 11, 2020 2:54:10 PM

Register for Two Upcoming NADCA-Sponsored Webinars

This series will look at, die sprays, plunger lubricants and their effect on casting quality. With an in-depth discussion of both die and plunger lubricants we will look at their chemistry, function, application and effects on casting production and quality. The course will review pulse spray, its application and results at two production facilities. Hydrostatic spray will also be reviewed with application examples and use of hydrostatic spray.

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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

Simulation of High Pressure Die Casting Process for Identifying and Minimizing Defects

Posted by Hill and Griffith Company on Oct 7, 2020 4:56:12 PM

Excerpt from the August 2015 article from the International Journal of Engineering Research & Technology by A. Advekar, Y. Arunkumar, and M.S. Srinath

Introduction

High-pressure die-casting (HPDC) process is widely used to manufacture a large variety of products with high dimensional accuracy and productivities. It has a much faster production rate in comparison to other methods and it is an economical and efficient method for producing components with low surface roughness and high-dimensional accuracy. All major aluminum automotive components can be processed with this technology. In this process, the metal is injected into the die at high speeds (30–100 m/s and typically 40–60 m/s for aluminum alloys) and under high pressure through complex gate and runner systems.

The mechanical properties of a die-cast product are principally related to the die temperature, the metal velocity at the gate, and the applied casting pressure. Die casting is a manufacturing process that produces geometrically complex metal parts through reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum). The differences between these machines will be detailed in the sections on equipment and tooling. However, in both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part, called the casting.

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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, Journal of Engineering Research and Technology

Top 3 Remedies for Defects Caused by Die Casting

Posted by Hill and Griffith Company on Sep 29, 2020 8:38:24 PM

Excerpt from the Manufacturing Technology Insights August 2020 article

The most common defects in die casting are caused due to misruns and cold shuts. Below are three remedies for common defects caused by die casting.

Fremont, CA: The die casting process forces molten metal into a cavity at high pressure and is commonly used to make automative parts like engine blocks, wheels, and engine chassis. The tooling producing these parts must be durable. Buyers are not likely to trust a new process easily. Die cast tooling is not a prominent place to experiment, but the challenge of the method makes it precisely the kind of application that is ideal for testing the limits of metal 3D printing.

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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 Webinars: Cooling Line Placement in New Die Steels

Posted by Hill and Griffith Company on Sep 23, 2020 5:17:31 PM

The material presented in this video are some highlights from NADCA’s online webinar - Cooling Line Placement in New Die Steels. Increasing productivity is important to the die casting industry. The R&D course, Cooling Line Placement in New Die Steels, addresses how close cooling lines can be placed to the cavity surface and why. This course includes an explanation of the technology and successful results of use.

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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

Prediction of Casting Defects in High-Pressure Die Casting Alloys

Posted by Hill and Griffith Company on Sep 16, 2020 5:23:49 PM

Excerpt from the January 2010 issue of Metallurgical Science & Technology by Giulio Timelli

I. Introduction

The increased use of light alloys in the automotive industry is, above all, due to the need of decreasing vehicle weight. The same need has to be taken into account in order to meet both energy and environmental requirements. In terms of application rates, Al and its alloys have an advantage over other light materials, such as Mg and Ti alloys. The reduced prices, recyclability, development of new improved alloys, increased understanding of design criteria and life prediction for stressed components and an excellent compromise between mechanical performances and lightness are the key factors for the increasing demand of Al alloys.

A great contribution to the use of Al alloys comes from improvements in casting processes, which allow to increase the production, to reduce the cycle time, and to manufacture complex-shaped castings with thin wall thickness. Among the recent casting techniques, the high-pressure die casting (HPDC) is largely used by the automotive sector since it fulfills the above advantages.

 

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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

 


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