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Die Casting News

Leaker Die Casting Defect May Be Reduced by Proper Use of Lubricants

Posted by Hill and Griffith Company on Aug 16, 2017 3:19:44 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • The leaker die casting defect is another form of shrinkage problems
  • There may not be any large voids, in fact, there may not be any visible porosity
  • All that is needed is a continuous path and enough space for gas or liquid to get through
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Reduce Die Casting Sinks by Proper Application of Lubricants

Posted by Hill and Griffith Company on Aug 8, 2017 4:56:06 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Die Casting Sinks (surface depressions) are a form of shrink porosity
  • A sink forms when the shrink porosity is close to the surface, and as it cools it pulls the thin skin on the die surface in towards itself
  • The shrink porosity is close to the surface because the surface of the casting is the hottest point in that area of the casting

 

  • Eventually, the casting solidifies with the sink in the surface
  • The clue that the spot is getting hot and that a sink might form is when the surface of the casting starts to get rough (or frosty in appearance)
  • The operator should notice this condition, and start to spray and/or adjust cooling line flow
  • What is needed is a change in temperature balance between the hot and cold areas

(Thanks to All About Metallurgy for posting this PDF. We'll cover other aspects of die casting defect control by the proper use of die casting lubricants from the course in upcoming blog posts)

(If you liked this article you might also like this post on, "Die Casting Defects")


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant and recommend release agents, 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, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Reduce Blisters by Proper Application of Die Casting Lubricants

Posted by Hill and Griffith Company on Aug 2, 2017 12:08:34 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Blisters are another version of gas porosity, the gas just happens to be near the surface of the casting.
  • The trapped gas is under high pressure at the end of fill and the metal may shrink and squeeze it more.
  • When the casting is taken out of the die, and the die surface is no longer there to hold the casting shape, pressure from the trapped gas is able to push up a blister.

 

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Gas Porosity And Surface Die Casting Defects

Posted by Hill and Griffith Company on Jul 26, 2017 4:57:41 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

Gas porosity is the biggest single problem in die casting. High gas content prevents heat treating or welding and makes strength unpredictable.

  • There are three major sources of gas porosity for die castings: Trapped air, Steam, Gas from lubricant
  • Gas porosity is round and generally smooth, although it can be flattened to some extent by pressure
  • The actions to reduce gas porosity, in general, are not the same as the actions for reducing shrink porosity
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Die Temperature And Surface Die Casting Defects

Posted by Hill and Griffith Company on Jul 19, 2017 3:43:19 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

The die temperature’s effect on surface defects and the die temperature operating window will be discussed next

  • A low die temperature affects surface defects by cooling the fluid metal stream and increasing the percent of solidified metal in the metal stream
  • If the percent of solidified metal is high, then it becomes stiff and solid and does not knit together well; And the flow forms "wrinkles", or cold flow
  • A cold die can be compensated for by having a shorter fill time - this means a higher plunger speed
  • In other words, we can exchange plunger speed for die temperature.
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Register today - NADCA Die Casting Show

Posted by Hill and Griffith Company on Jul 14, 2017 9:18:54 AM

Registration Now Open for NADCA’s Die Casting Congress & Tabletop

The 2017 Die Casting Congress & Tabletop will be held September 18-20, 2017, at the Atlanta Convention Center at the AmericasMart in Atlanta, GA. This three day event will feature more than 100 exhibitors ready to highlight their latest and greatest products and technology. Over 30 Congress presentations will be given by experts from around the world on topics such as computer modeling, process engineering, advanced technology, additive manufacturing and a special Global Trends spotlight session, just to name a few. These presentations will expose metalcasters to the latest technology, ongoing research and successful management tools that will assist companies in enhancing their competitiveness.

NADCA Die Casting Show
September 18-20, 2017
Atlanta, GA
Hill and Griffith Booth #225
More Information »

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

NADCA EC-515 Die Casting Defects Course Review

Posted by Hill and Griffith Company on Jul 5, 2017 2:57:11 PM

Basics for controlling die casting defects - By Dr. Steve Midson

  • The scrap report should be available to everyone in the plant. In fact, it should be posted on the bulletin board so everyone can see it.
  • The scrap reporting system must be set up for those who have to make improvements, not just for the front office.
  • You can’t correct and control defects without first measuring and reporting them.
The daily scrap report must have the following features as a minimum:
1. It must be available first thing in the morning for the previous day
2. It must categorize scrap (as a minimum): By defect type, By part number, By die, By shift, By operator, By machine. Read More

Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Die Casting Surface Defect Prevention - NADCA Course highlights

Posted by Hill and Griffith Company on Jun 28, 2017 4:22:06 PM

NADCA Video News Update: Die Casting Defects - Surface Defects Part I

There is not one single person that is responsible for die casting surface defect prevention. Everyone must participate. It’s not just the die casting tool room, die cast part designer, die casting machine operator, die casting machine set-up person, die casting inspector, etc. Anybody that is adding some value and designing the overall part has a role when it comes to minimizing defects.



The first two factors on the list, the wall thickness and the overall casting shape, are controlled by the part design - but they are very important as far as contributing to the surface defect problems. The wall thickness is the most critical, and controls:

  • Fill time required
  • Die temperature required
  • Distance the metal will flow
  • Length of defect free surface that can be made when we cast the part
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, Die Casting Surface Defect Prevention

High Performance Vacuum Assist Die Casting Video

Posted by Hill and Griffith Company on Jun 21, 2017 10:00:00 AM

Today's video comes from KenWalt Die Casting. It highlights their unique vacuum assist die casting process for large zinc and aluminum parts. Vacuum assist gives you a denser casting with less chance of porosity.

"My father and my goal was always to make the best die casting. Not just make a die casting. Anybody can put metal in a pot and make a casting. Does it serve its function. Does it do its job. Does it give you the product you need and the sustainability of that product," states the current owner Ken Zaucha to start this tour of their facility.

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, Vacuum Assist Die Casting

Thermal Control of Die Casting Dies for Optimal Performance

Posted by Hill and Griffith Company on Jun 14, 2017 9:47:24 AM

Controlling the temperature of a die casting die through the location of cooling lines is critical to performance and die life.

A properly designed system of water and/or oil lines will process heat energy so the die can be operated productively with the highest part quality possible. NADCA has created a three level approach to addressing thermal control. This series is broken down by beginner, intermediate and advanced courses suitable for people with varying levels of knowledge in this area.

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, Thermal Control of Die Casting

 


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant and recommend release agents, 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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We are pleased to provide samples in quantities large enough to allow you to "try before you buy." Die Casting and Squeeze Lubricants- Diluco®, Permanent Mold Coatings- Concote™, Plunger Lube™- Graphite and non-graphite oils and pastes with excellent anti-wear properties, Casting Operations Products: Start-up lubes, Ladle coatings, Anti-soldering pastes, 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, Way oil knuckle lubes and Metalworking Fluids- Grifcut™

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On-site process surveys, Casting defect investigations, Product testing, Tooling start-ups and Statistical process controls and much more. Also, lab facilities are available to provide testing upon request. 

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