Die Casting News
Setup, Startup, Warm-up, Shutdown and Safety - Learn to Properly Operate the Die Casting Machine with courses from the North American Die Casting Association.
This year NADCA will be focusing on presenting thier Nation Courses in webinar format. This will allow participants to gain a thorough understanding of the subject matter without the additional cost of travel. There is also the option to attend all courses in a designated Level in order to fulfill certification requirements. NADCA's Operating the Die Casting Machine series is next up on their 2017 course list. Operating the Die Casting Machine is a course detailing the basic die casting setup, startup, warm-up and shutdown.
The material presented in this video are some highlights from NADCA’s online webinar – The Role of Die Casting Lubricants – presented by NADCA’s Beau Glim. 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. The full presentation discusses 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.Read More
Film-forming lubricating oils, solid lubricants, waxes, or fluids that prevent other materials from sticking or adhering to an underlying surface are called mold releases and release agents. Unlike permanent non-stick coatings, release agents typically require replenishment and are non-curing.Read More
Some basic features are common for all kind of release agents (R.A.). They are:
- Incompatibilty with the product to be demoulded both chemical and physical. If moulded material absorbs the release agent, release power is extremely poor and surfacial defects are highly probable. Lubricating effects to help moulded material flow and moulded item extraction.
- R.A. should not be washed off mechanically by moulded material flow.
- In the case of die casting a basic property is thermal resistance at high temperature.
- Materials technically available in die casting release agents formulation are mineral oils, special silicones, waxes and esters.
- We need also surfactants because our products are water based.
- The job in formulating release agent is mostly empirical and requires a lot of experience. A set of analysis the obtain a coherent picture of thermal resistance of materials commonly used was not exaustive because of the instruments limitations.
- Die casting R.A. are water based because the water evaporation heat is very useful to cool down moulds. For this reason are used at high dilution.
Photo of "Best in Class" Magnesium Front Sub-Frame, Meridan Lightweight Technologies Inc., Ford Motor Company, Strathroy, Ontario Canada on display at the 121st AFS Metalcasting Congress, April 27, 2017, Milwaukee, WI.
Material: AE44 Magnesium
Process: Cold chamber high pressure diecasting
Weight: 23.1 lbs.
Application: Automotive mounting structure for steering, gear, sway, bar and engine roll restrictor. Originally designed as a weldment of steel stampings, the magnesium diecast structure reduced mass by nearly 9 lbs. and consolidated 15 parts into one large casting with corrosion mitigation and load distribution parts. The subframe was a CAE-driven design with stringent stiffness targets. The final design met all stiffness, durability, dimensional, and strength performance requirements, as well as requirements for elevated temperature proof load at attachment points.
Innovative Die Castings Wanted - Submit Your Entry to the International Die Casting Design Competition
Regular reviews and benchmarks are important for successful die casting process evaluationsHill and Griffith offers this helpful Die Casting Process Evaluation Form to submit your input.
Here's great video describing both the hot and cold chamber die casting process by Mechanics Tips.
Mercury Marine's new high-pressure die casting machine is now the largest in North America
FOND DU LAC, Wis., April 3, 2017 -- Mercury Marine, the world's leading manufacturer of recreational marine engines held an event today to officially announce commissioning of the largest high-pressure die casting machine in North America. Since 2009, Mercury Marine has now invested more than $800MM in R&D and manufacturing expansion at its Fond du Lac campus.
This specific investment is a 4,500 ton Buhler-Prince machine. Installation began late in 2016 and was just completed in late March 2017.
"This new machine positions us to make castings that no one else in the industry can do," said Mike Meyer, general manager Mercury Castings. "With this new machine, Mercury can make larger, lightweight structural components and reduce the overall weight of our engine by producing more efficient castings."
(Photo from Lake County, Mercury Marine Dealer)
CONCOTE™ permanent mold coatings formulated with special refractories, binders, wetting agents, and preservatives.
CONCOTE™ products provide a thin continuous film between the surface of the die and the castings.
Desired Surface Finish
Good Lubricity and Insulation
Good Release Properties
Prevents Premature Die Failure
Video from FLOW-3D, "Simulation of a low pressure die casting showing the filling temperature of a tire rim using FLOW-3D Cast."
Hill and Griffith Customer Service
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.
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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.