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Die Casting News

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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8 Die Casting Defects: Root Causes in Processes and Their Remedies

Posted by Hill and Griffith Company on Sep 9, 2020 10:26:46 PM

Excerpt from the March 2017 issue of International Journal of Engineering Research and Application by Vaibhav Ingle and Madhukar Sorte

I. Introduction

Casting is a manufacturing process where hot molten metal is poured into a mold to solidify as a casting. Castings are most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Casting is a process which carries risk of failure occurrence during all the process to complete the finished product. Hence, action should be taken while manufacturing cast products so that defect-free parts are obtained. During the casting process, there is always a chance where defects will occur. Minor defects can be adjusted easily but high rejected rates could lead to significant change at high cost. Therefore, it is essential for die casters to know and identify the type of defect, the exact root cause, and their remedies. In this review, an attempt has been made to provide all casting related defects with their causes and remedies.

 

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NIOSH Recommendations for Control of Occupational Safety and Health Hazards: Foundries

Posted by Hill and Griffith Company on Sep 8, 2020 4:51:54 PM

Expert from the NIOSH publication that provides recommended guidelines for the health and safety of foundry workers.

IV. Engineering Controls

The foundry environment may be a potential source of numerous toxic air contaminants such as silica, CO, and thermal decomposition products; physical hazards such as noise, heat, and vibration; and safety hazards, including contact with molten metal. The short- and long-term health and safety effects fo the potential hazards, in general, and illustrated how they may affect foundry workers are reviewed in Chapter III. To reduce worker exposure, foundry hazards must be adequately identified and evaluated, and engineering controls, administrative controls, work practices, and, when appropriate, personal protective clothing and equipment should be applied. Ventilation, enclosures, barriers, and substitution of less toxic materials and hazardous processes can be utilized to help control safety and health hazards in different foundry operations. 

To improve working conditions in foundries, proper consideration should be given to controlling dust and fumes, especially silica dust, by engineering methods. A plant that is well-designed from environmental and production standpoints will have a substantially reduced need for dust control. However, when a plant design is not adequate to eliminate the dust and fume hazards, retrofit control procedures must be introduced.

 

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NADCA Webinars: Die Casting Defects

Posted by Hill and Griffith Company on Sep 2, 2020 9:47:26 PM

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Defects - presented by Dr. Morris Murray of M. Murray & Associates. Morris discusses gas porosity and its major sources, and goes into some detail on each source.

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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

New Approach Improves Die Casting for Engine Blocks

Posted by Hill and Griffith Company on Aug 26, 2020 3:06:43 PM

An automobile engine block is made of two distinct, functional units: the cylinder block (the upper part housing the cylinders), and the crankcase (lower part housing the crankshaft.

Article excerpt from the June 2007 issue of Foundry Management & Technology by Wally Huskonen

An automobile engine block is made of two distinct, functional units: the cylinder block (the upper part housing the cylinders), and the crankcase (lower part housing the crankshaft. Die casting in aluminum has proven to be an option for producing these engine castings, offering high output and flexibility in component design. The approach may grow even more attractive following the development of a new die casting machine design and changes in the die making process.

 

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Release Agents for Cold Box Die Casting Core Production

Posted by Hill and Griffith Company on Aug 19, 2020 4:51:59 PM

Article excerpt from the September 2017 issue of Foundry Trade Journal by S. Clifford and H. Rehse

There are several different types and formulations for release agents used in the cold box process. In highly stressed areas of the core box, traditional release agents do not function well. A new resistant release coating based on novel technology that adheres to the core box has been developed and introduced into foundry production to combat resin wipe-off. Trials ran to monitor the number of cycles before the release coating needed re-application. Data is presented from the trials. The testing shows the coating to be effective up to several hundreds or even thousands of cycles between applications.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, FOUNDRY Management & Technology, Die Casting Lubricant, Die Casting Process, die casting lubricant management

Reduction of Blowholes in Aluminum High Pressure Die Casting Machines

Posted by Hill and Griffith Company on Aug 12, 2020 8:43:40 PM

Excerpt from the August 2018 article from the International Journal of Engineering & Technology by P. Nagasankar, et.al.

Abstract

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defects found through why-why analysis technique. Process capability of current high pressure die cast manufacturing is checked. The current problem of blowhole defects are solved by making an improvement in design of the die inserts. In-gate directions are changed to obtain modified improved flow patterns. Using magma flow simulation software, existing and modified design is compared. It is found that modified design shows superior results, and using this, the defect of blowholes is minimized satisfactory.

 

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High Integrity Die Casting Processes

Posted by Hill and Griffith Company on Aug 5, 2020 8:46:06 PM

Defects in High Pressure Die Casting Processes

Excerpt from the instructional book by Edward J. Vinarcik

11.1 Introduction

Casting processes are inherently complex due to the phase transformation from liquid to solid metal, which creates all geometric features as well as material properties. With such an intricate process, many potential defects may result. Potential defects related ot high integriy die casting are presented in this chapter. Defects encountered in conventional die casting will be introduced but will not be discussed in detail, as several texts are available that examine these issues. Defects unique to high integrity die casting processes will be discussed in greater detail.

11.2. Conventional Die Casting Defects

Many potential defects commonly found in conventional die casting can also occur in hight ingegrity die casting. often these defects are avoidable if basic guidelines are followed related to component design, equipment selection, die design, process design, raw material quality, process control, die maintenance, equipment upkeep, and material handling. Conventional die casting defects can be divided into three categories: surface defects, internal defects, and dimensional defects. Each category will be discussed separately below.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, FOUNDRY Management & Technology, Die Casting Lubricant, Die Casting Process, die casting lubricant management

NADCA Webinars: Alloys for High Integrity Die Casting

Posted by Hill and Griffith Company on Jul 29, 2020 1:22:42 PM

The material presented in this video are some highlights from NADCA’s online webinar - High Integrity Die Casting: Alloys for High Integrity Die Casting. In this webinar, all aspects of aluminum high integrity die casting alloys will be covered: from AA numbering, basic metallurgy, the role of alloying each element, impurities and their impact on part quality and properties, all the way to different alloy families and existing alloys currently used or under development, with their advantages and disadvantages, current and potential applications as well as achievable properties (using different heat treatments) with each of them.

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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

 


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