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Die Casting News

Die Casting Lubricants: Science or Black Art?

Posted by Hill and Griffith Company on Oct 27, 2016 9:25:36 AM

  • 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.

    2. Even then, there are issues that are not clearly explainable. For instance, it is not uncommon for a trial die lubricant to work well on one casting and yet create problems on a similar casting running on the machine next to it. This causes many to ask the inevitable question,” Why?” There are no simple answers to this question. In spite of the fact that die lubricant manufacturers know more now about the physical and chemical properties of their products and their potential performance in the die casting environment, there are still intangibles within the die casting process that are often overlooked during product selection. Some of these intangibles are variations in types of castings, cycle times, die design, water quality, machine equipment etc……  Because each of these variables has an effect on the thermal balance of the process, they impact the performance of the die lubricant, which in turn impacts the quality of the casting, the scrap rate, downtime and finally the profitability of the company. The purpose of this paper is to look at areas where the die caster and die lubricant manufacturer can work together to improve the development and functionality of a die lubricant specific to their process, resulting in a superior casting, reduced scrap and downtime, and ultimately increasing the bottom line. There are four areas that need to be focused on: 

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application, Die Casting Awards

2016 Die Casting Award Competition Winners

Posted by Hill and Griffith Company on Oct 19, 2016 5:37:19 PM

We exhibited at the Die Casting Congress and Tabletop event in Columbus on September 26 and photographed the display of die casting award winners. Congratulations!

From the North American Die Casting Association site.

PURPOSE: Promote increased use of die castings by recognizing and publicizing outstanding designs.

ELIGIBILITY: Entries will be judged in several categories of: Aluminum, Zinc and Magnesium die casting. In addition, we will be accepting castings from other alloy families as well! Both custom and captive casters are eligible.

AWARDS: One winning casting will be awarded per category. An award will be presented to the casting supplier and the customer.

JUDGING: There are four equally weighed criteria: ingenuity of casting/product design; overall quality; cost savings & contribution to expanding the market for castings. A panel of independent judges, acknowledged experts, with no ties to eligible casters, will choose the winners. The judges’ decisions are final.


Zinc Die Casting Over 6 oz
Bruschi s.p.a, Via Mendosio, 26, Abbiategrasso, Milan, Italy

Caster Award Nominees - Erminio Fuse
Customer - ARCA Technologies
Function of Part
Frame for PCB and scanner installed in a "Teller Cash Recycler."
Previous Process to Produce Part
Several stainless steel parts welded, assembled with screws, welded and machined.
Advantages Gained
Zinc die casting has eliminated the assembly of the steel frames, now only 2 die cast parts. parts are now cast to near finished condition, removing CNC machining operations (only need tapping ater shot blasting). Increased stiffness of the part provides improved performance of the scanner. Overall cost reduction of 40%.
Part - Mobile Frame
Material - Zamak 5
Weight - 10.25 oz
End Market - Office Equipment

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application, Die Casting Awards

NADCA Die Casting Soldering Mitigation Video Offered

Posted by Hill and Griffith Company on Sep 28, 2016 9:25:20 AM

From NADCA eNews Sep 28, 2016

The material presented in this video are some highlights from NADCA’s online webinar - Ways to Mitigate Die Casting Soldering - presented by Steve Udvardy. For information on purchasing a downloadable copy of this webinar in its entirety, please click here. To view this video highlight, please click here.

From the video transcript, "Now let’s take a look at the variables that affect soldering. And those are Velocity, Impingement Angle, Metal Pressure, Die Spray, Temperatures, Casting Alloy Composition plays a roll as well. And as you might guess, proper control of these variables can lead to the mitigation of solder. But there are few additional items that we can add to our list, Die Design Features, Die Coatings and Surface Treatments and the various different types of die steels. We’ll discuss each of these in more detail. These are the things that we want to control, attack, get into our process parameters or preferred values in our parameters. And certainly, when we design the die keep some of the features in mind, consider surface coating treatments and alternate materials."



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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application

High Pressure Die Casting Release Agent Spray Manifold

Posted by Hill and Griffith Company on Aug 24, 2016 10:28:50 AM

Published on July 12, 2016 by GF Automotive (George Fischer) presents this video, "The innovative lightweight components from GF Automotive in casting make modern cars lighter and help reduce CO2 emissions. With proprietary, cutting-edge materials, bionic design and advanced manufacturing technologies, GF Automotive global automotive and commercial vehicle industry solutions to their current burning challenges."

(This is a frame grab of the high pressure die casting release agent manifold shown in the video. The intricate nozzle patterns are adjusted to the specific mold being used. Exacting control of the release agent spray pattern controls the cooling of the mold and provides accurate release agent application.)

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Die Casting Supplies, Foundry Supplies, Die Casting Release Agent Application

High Pressure Die Casting Release Agent Application and Simulation

Posted by Hill and Griffith Company on Aug 17, 2016 5:31:11 PM

(For this week's news item, ESI Group presents "Filling, solidification, stress with pouring, shot sleeve, piston for a real injection simulation made by MOFOPRESS and ECOTRE using ProCAST" shows application of die casting release agent.)

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Foundry Supplies, Die Casting Release Agent Application

Global Die Casting Release Agent Market - Trends, and Forecasts

Posted by Hill and Griffith Company on Aug 10, 2016 1:26:48 PM

(Thanks to Mordor Intelligence for this week's news item. We've included their description of the paper here. You can learn more and download a sample here. Hill and Griffith's die casting release agents are proud to be a part of this growing industry.)

Global Die Casting Market - Growth, Trends, and Forecasts (2015-2020)

The global die casting market was valued at USD 55.47 billion in 2015 and is projected to reach USD 76.345 billion by 2020, at a CAGR of 6.60% during the forecast period from 2015 to 2020.

Rules levied by OSHA and initiatives by NADCA to improve the technical workforce in the die-casting industry are expected to improve the overall production of the die-casting market. NADCA is working with several community colleges in the United States to create a die-casting farm system. This initiative was undertaken mainly due to the increased automation and a demand for higher skills from the workforce. The end market for die-casting is quite prolific and saw an increase of 17.1 million units in 2015 from 16.3 million units in 2013. The market for magnesium die-casting is expected to grow at a higher CAGR of 10.0% over the coming 5 years, while that of zinc is expected to grow at a slower pace.

The automobile industry is highly dependent on the Environmental Protection Agency regulations, owing to the high emissions of the automotive units. The move by the EPA to raise the mile per gallons standards to 35.5 mpg by 2016 and then 54.5 mpg by 2025 has actually helped the die-casting industry, as the auto industry concluded that the only way they can get to those mileage standards is by light-weighting the vehicles. Aluminum, and specifically aluminum die-castings in many of the power train and engine areas is the one important way in which they could achieve this. This is one of the major reasons for the predicted growth of the industry in the area of structural die-castings as well.

The global die-casting market is segmented on the basis of production process type, application type, raw material type and geography.

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Foundry Supplies, Die Casting Release Agent Application

Two Automotive Diecasting Plants Expanding

Posted by Hill and Griffith Company on Aug 2, 2016 1:13:32 PM

(Thanks to Robert Brooks editor of FOUNDRY Management and Technology for this week's news item.)

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Foundry Supplies

Start Planning Now to Have Your Die Casting Plant Participate in Manufacturing Day

Posted by Hill and Griffith Company on Jul 27, 2016 2:44:00 PM


Coming up quickly is the fifth annual edition of Manufacturing Day, October 7, 2016, meant to inspire the next generation of manufacturers. Hundreds of industry-leading organizations will do their part to promote careers in manufacturing to students, community leaders and others. Companies joining the Manufacturing Day celebration can host plant tours and informational sessions, to spread the word about the exciting and rewarding opportunities that exist for the next generation of workers in our industry. Other options including organizing or participating in manufacturing-related community events that include several companies; and conducting job fairs and educational fairs. This is your chance to address common misperceptions about manufacturing, and connect with future generations to help ensure the ongoing prosperity not just of your company, but of the entire industry. Start with a visit to the Manufacturing Day website: www.mfgday.com to find tours near you. Here is a PDF "Maunfacturing Day Host Toolkit" that explains how to host an event at your plant.

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Manufacturing Day, Foundry Supplies

Global Automotive Die Casting Lubricants Market Expected to Grow at 9.4% Through 2020.

Posted by Hill and Griffith Company on Jul 13, 2016 4:40:25 PM

(Our post for this week comes from Mordor Intelligence's description of the global die casting lubricant industry.)

Technological advancements have led to the development of highly engineered die lubricants that can be tailored to enhance the die-casting process, allowing them to gain additional efficiency. The market is expected to grow at a Compound Annual Growth Rate of 9.24% through 2020. Die lubricants provide their effectiveness where they can be engineered to optimize wetting and spreading times, promote metal flow, quickly cool die surfaces and maintain a die temperature within a narrow band, all of which allow for faster cycle times and longer die life.

The drive for improved fuel efficiencies in the automobile industry has led to continuous developments in the die-casting materials and technologies, as manufacturers strive to reduce the weight of automobiles by replacing steel with light metal components. There has been a significant evolution in automotive die-casting over the last thirty years from relatively small parts to the casting of very large parts, such as engine blocks of a vehicle. The parts are frequently made from relatively high melting alloys of aluminum or magnesium and are cast at very high pressures to ensure complete cavity fill. As die-casting conditions require severity of temperature, pressure and increased part size, the need for lubricants arises to enhance the process.

A high-pressure die-casting machine has many moving parts that require lubrication. The main types of lubricants required for the die-casting machinery are: die lubricants, plunger lubricants, and trim press lubricants. These are the areas where thermal stresses are maximum as a result of exposure to the molten metal. Unique, robust and formulated products are developed to serve as plunger lubricants and die lubricants that meet the needs of extremely harsh conditions faced by the machinery.

Water-based lubricants, called emulsions, are the most commonly used lubricants because of environmental and safety reasons. These types of lubricants are useful since if the water in the solvent is properly treated to remove all minerals from it, it will not leave any by-product in the dies, unlike mineral based solvents. The negative health implications of solvents and compliance with local environmental standards have enabled advanced water-based lubricant products.

The market is primarily dominated by Asia-Pacific countries, followed by Europe. The market is quite fragmented with the presence of many regional players.

The market is segmented by type, application, die-casting metal and geography.

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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Hydraulic Fluids, Foundry Supplies

Technical White Paper Review - "Release Agents for Die Casting: General Aspects and State of the Art"

Posted by Hill and Griffith Company on Jul 6, 2016 2:21:10 PM

(For this week's Die Casting News, we'll republish the highlights of this technical paper by Dr. Giovanni Rampi Jodovit s.r.l. - Lonate Pozzolo - Italy. View the entire document here http://www.jodovit.com/doc/HTDC%20English%20.pdf)

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

 


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