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Die Casting News

NADCA Video: Using die casting lubricants to prevent shrink porosity

Posted by Hill and Griffith Company on Jan 31, 2018 4:35:47 PM

NADCA Video News Update: including using die casting lubricants to cool die and prevent shrink porosity

The material presented in this video are some highlights from NADCA’s online webinar - Defects in Die Casting: Porosity Defects and their Causes. Porosity is the biggest problem for die casters and is the most common cause of rejecting a part. This first webinar covers the various types of porosity and how to identify them. It is important to realize that porosity can have a combination of causes rather than just one “magic bullet” solution.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: diecasting.org/store/detail.aspx?id=WEB227

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Tags: Die Casting, Die Coatings, die lubricants

The days of using die casting lubricants to control die temperature is over.

Posted by Hill and Griffith Company on Jan 24, 2018 11:16:51 AM

NADCA Video News Update: Engineering Die Casting Dies: Dimensional Repeatability

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.

(A transcript from the promotional video excerpt.) 

"Things can change that can change dimensions. Cooling time, the time the casting is in the die. The steel die is very, very strong aluminum or zinc, or whatever is not, so the longer you hold it in the die, the more the casting will have the dimensions of the die. There is a limit because if you go too long, the casting will crack, but the closer you want to dimensional tolerance, the longer your cooling time usually is, not always, but usually is. Steel guides are very, very strong.

Metal temperature, as you increase your metal temperature or decrease your metal temperature, the amount of heat going into the die changes, so you are now getting castings that are different in dimensions.

Die temperature across the insert - if you have the left side of your die is hotter than the right side, then the casting coming out will usually be hotter on the left side than on the right. As it starts to cool, the left side has to cool more, so it will shrink more, so the casting will warp. You start to get dimensional changes, difference from left to right. That's why cooling of the die is so important. Internal cooling is critical to controlling dimensional accuracy. We have produced castings with extreme flatness, extreme dimensions, and it all comes down to, or part of it comes down to controlling the die temperature and making it consistent.

Spray time, the days of spraying the die to control die temperature, in many plants, is over. The spray is to add the lubricant and to cool certain sections, which you cannot cool internally. For example, the fins on an air cooled motor. It's very hard because there are a number of cores in there, but most of the time, die spray is down to a minimum. We are consistently using die sprays on 2,500-ton machines where the die spray time is a second or .8 of a second to get accuracy. Die spray pattern, again, the same thing. You change your die spray pattern, you will change your dimensions of your casting.

Pre-heating of dies, if you use a blue flame, a strong gas torch, then you are heating the dies in certain spots. When the aluminum or zinc, or magnesium, or brass starts going into it, it changes the profile, so there is a difference between the first few shots coming out and the last, the shots during production when the die has become stable. People say, "How many die pre-heats should I do?" There are many ways of finding out, measuring die temperature, measuring the quality of the part, measuring the accuracy, but it's worthwhile doing it. There is no magic rule that says make three castings; everything will be fine. It depends on your plant. It depends on how you design your dies.

Die flash, that's an obvious one. You flash the die; you slowly build up metal on the joining faces. The die splits, and then your dimensions across the die are changing. The die flash builds up until it gets to a certain level, and then either an operator removes it, or the die spray blow blows it away. That gives you changing dimensions.

In the modern plant, die flashing is something that is attacked very, very definitely to make sure that it does not happen. There are a number of plants internationally, which do not have die flashing.

Soldering, or soldering, that's where metal sticks to the die. It chemically attacks to the die, so you can have, in one section of the die you get soldering, as the casting's ejected, it sticks on that spot. It's more difficult to eject, so the casting bends. You can get it on cores, and as it slowly builds up, you are losing dimensional accuracy. The diameter is increasing. If you're using coatings, if you're using jet cooling, if you're using a number of things, you can postpone soldering a lot. Very difficult to get rid of it, but you can postpone it coming.

There are many, many other things that can change."

To purchase access to this course, visit the NADCA Marketplace at www.diecasting.org/store. Purchasing a course through the Online Education System grants you one year of access to the recording, presentation, support material, and test when applicable.

About the North American Die Casting Association
Headquartered in Arlington Heights, IL, the North American Die Casting Association (NADCA) represents the voice of the die casting industry, representing more than 3,100 individual and some 300 corporate members in the United States, Canada and Mexico. NADCA is committed to promoting industry awareness, domestic growth in the global marketplace and member exposure.


Die Casting Process in Google News:

Die Casting Machine Market Statistics, Forecasts till 2022

Automotive Die Casting Lubricants Market : Die Lubricant to Grow at 5.2% CAGR During 2017-2025


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, die casting lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

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Tags: Die Casting, Die Casting Lubricants, Die Coatings, die lubricants

Die Casting Classes Including Die Cooling and Die Casting Lubricants

Posted by Hill and Griffith Company on Jan 17, 2018 2:09:43 PM

Back By Popular Demand - NADCA National Courses Winter Semester

NADCA has received quite a bit of interest this past year for National Courses. This winter NADCA will be holding a series of courses at their Headquarters in Arlington Height, IL.  From January 8 to February 14 NADCA they be offering the following courses. 

Die Cast Problem Solving - January 23 - A one day course designed to solve difficult die cast problems that can't be solved through conventional process engineering methods.
Pricing: Corporate Member $300, Individual Member $345 and Non-member $405

Die Casting Defects - January 24 - A one day program devoted to understanding and identifying the probable causes of defective die castings and to determining and implementing solutions that minimize or eliminate the effects of the problem.
Pricing: Corporate Member $300, Individual Member $345 and Non-member $405

Gating Design & PQ2 - January 29 - 30 - A two-day program devoted to understanding and implementing a proven process for designing and calculating effective gating based on the specific feature of the die, the casting and the power performance of the machine. This course features the New Gating Equation.
Pricing: Corporate Member $500, Individual Member $575 and Non-member $675

Engineering Die Casting Dies - January 31 - February 1 - A two-day program dedicated to providing the process, techniques and references on how die casting dies should be designed to perform the functions required.
Pricing: Corporate Member $500, Individual Member $575 and Non-member $675

Product Design - February 13 - A one day program dedicated to understanding the die casting option and the unique capabilities and advantages that die casting brings to the metal forming market. The workshop also focuses on the principles, concepts and techniques needed to optimize the design of die casting products.
Pricing: Corporate Member $300, Individual Member $345 and Non-member $405

Computer Modeling - February 21 - A one day introduction to the uses and applications of computer simulation in die casting.
Pricing: Corporate Member $300, Individual Member $345 and Non-member $405

Do not miss out on your chance to gain valuable knowledge about die casting parts and processes! To register for a course or courses in the winter semester click here. If you have any questions please feel free to contact Melisa Ryzner, CMP at 847.808.3161 or via email at mryzner@diecasting.org.

About the North American Die Casting Association
Headquartered in Arlington Heights, IL, the North American Die Casting Association (NADCA) represents the voice of the die casting industry, representing more than 3,100 individual and some 300 corporate members in the United States, Canada and Mexico. NADCA is committed to promoting industry awareness, domestic growth in the global marketplace and member exposure.


Die Casting Process in Google News:

Die Casting Machine Market By Product Types & Application, Top Manufacturer, Regional Analysis & Forecasts To 2023

Die Casting Machine Market 2022: Growth Factors, Key Companies, Cost Structure and Forecast


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, die casting lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Read More

Tags: Die Casting, Die Coatings, die lubricants

NADCA Video: The Need for Proper Die Cooling and Die Lubricants

Posted by Hill and Griffith Company on Jan 10, 2018 6:55:47 PM

NADCA Video News Update: T6 Heat Treating of Strontium Modified, Low-Iron Conventional Die Castings

The material presented in this video are some highlights from NADCA’s online webinar - T6 Heat Treating of Strontium Modified, Low-Iron Conventional Die Castings. This series explains chemical composition and physical properties of common alloys used in die casting. The course walks through the die casting process and explains the need for proper die cooling and die lubricants.

Click here for information.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: www.diecasting.org/store/detail.aspx?id=WEB250

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Tags: Die Casting, Die Coatings, die lubricants

NADCA Update 1-3-18: Features Educational Session on Die Coatings

Posted by Hill and Griffith Company on Jan 3, 2018 5:09:50 PM

Video News Update: Introduction to Die Casting: Die Casting Alloys & Fundamentals



The material presented in this video are some highlights from NADCA’s online webinar - Introduction to Die Casting: Die Casting Alloys & Fundamentals. This series explains chemical composition and physical properties of common alloys used in die casting. The course walks through the die casting process and explains the need for proper die cooling and die lubricants.

Click here for information.

For information on purchasing a downloadable copy of this webinar in its entirety, please visit: www.diecasting.org/store/detail.aspx?id=WEB205

 




(This post section's content is from the NADCA Update email 1-3-2018)

NADCA's Congress West is Quickly Approaching - Register Today

NADCA is excited to announce the return of Die Casting Congress West on January 11-12, 2018 at the Hilton Long Beach. The Congress will feature technology highlights of our Congress in Atlanta earlier this fall. The event will kick off with a cocktail reception on January 11 and lead into a full day of presentations on January 12.  Presentations to include: 


Session: State of the Industry
An update on the current state of the die casting industry.
Paul Brancaleon, North American Die Casting Association 

Session: Structural
The ability of the die casting industry to improve cast component performance will help die casting continue to be a relevant manufacturing process. Structural die castings have been identified as having the potential to expand markets for die castings by providing improved mechanical properties. Higher strengths and elongations allow die castings to be used as structural, or even crash-worthy, components on automobiles. Research on alloys and heat treatments used in structural die castings will be presented during this session.
Paul Brancaleon, North American Die Casting Association 
 
Session: Die Coatings  
Die casting is a harsh environment for dies and tooling. Heat checking, soldering and wash-out are all issues that die cast tooling faces. Research is being performed on the use of coatings to not only protect the tooling, but also reduce the amount of die spray needed. Protecting the surface of the die, as well as the shot sleeve inner diameter, will extend the life of the die and sleeve, which in turn leads to better quality castings.
Steve Midson, The Midson Group
 
Session: Computer Modeling
To make higher quality die castings the die casting process needs to be understood on a fundamental level. Transforming the basic principles of die casting into mathematical equations, the process can be simulated on a computer. Advances in computer simulation lead to process improvements, improved tooling, and optimum utilization of new alloys.
Al Miller, The Ohio State University

Session: Advanced Technology    
Customers are constantly looking for higher quality parts at lower costs with shorter lead times. There are limits to the benefits of improving process control. Eventually, new technology is required to meet the demands of new products or stricter quality and functional requirements. This session will look at some of those new technologies and how they can be utilized to improve die castings.  
Beau Glim, North American Die Casting Association

The Congress is sponsored by a limited number of Suppliers that attendees will be able to meet with to learn more about products and services available to the die casting industry.

Sponsors Include: 
Thermtronix Corp
BuhlerPrince Inc
Visi-Trak Worldwide, LLC
Frech USA Inc
B&L Information Systems Inc
Oerlikon Balzers
MAGMA Foundry Technologies Inc
Hill and Griffith Company
Hildreth Manufacturing LLC
Midland Technologies, Inc
Anviloy By Astaras Inc
HPM North America Corporation

The cost is just $20 for NADCA Members and $50 for Non-Members (note that registration includes access to the cocktail hour as well as breakfast and lunch on January 12).  In addition, if you will be sending 5 or more people we are offering special pricing.  

Information and registration can be found here.  If you have any questions please feel free to contact Melisa Ryzner, CMP at mryzner@diecasting.org or 847.808.3161.

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Tags: Die Casting, Die Coatings

 


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