The die casting industry depends on the skill of the machine operator for efficient production of high-quality products.
The effective machine operator understands the basic function of the process, the proper care of the die casting machine, die setup, recognition and control of basic casting defects, and the procedures that ensure his/her personal safety.
The North American Die Casting Association has created an eleven part webinar series geared towards educating operators on the do's and don'ts of running a die casting machine. Signing up for all eleven parts of this series will also grant you access to these courses through the NADCA Online Education System, which allows you to view the recordings, pdf's and support material for a full year.
The 11 parts consist of:
Title: Introduction To Die Casting & Safety on the Shop Floor
Date: Aired previously
Title: Understanding Metal Melting/Handling for Operator
Date: February 13, 2019
The operator will learn the proper way to handle molten metal at the die casting machine. This course will include the do's and don'ts of proper metal handling. Details will be provided on the common problems encountered when melting and handling molten metal. In addition, the type of defects that result from poor metal handling on and in the die casting and how these can be prevented will be discussed.
Title: Machine Components & the Die Casting Cycle
Date: February 14, 2019
The operator will learn what the basic die casting machine components are called and how they function as a system to produce a high quality die casting. Operators will be taught why monitoring and controlling the machine components is important for creating a successful shot. This course will address the eight steps of the casting cycle and what to look for in each step, to assure a high quality die casting is produced.
Title: How It Works - The Shot End
Date: February 19, 2019
The operator will learn the basic components on a die casting machine shot end, and the function of these components. Potential failures of the shot end will also be covered.
Title: Why Shot Monitors Are Important
Date: February 20, 2019
The operator will learn the components of a basic shot profile, and how it is monitored. Critical components such as jogging past the pour hole, critical slow shot, fast shot, switchover, deceleration, and intensification will be addressed. These concepts will then be connected to their effect on casting quality.
Title: Die Components & Their Functions
Date: February 21, 2019
The operators will learn the basic components of a die and their function. In addition, this course will cover the importance of proper clamping practices and the basic components of a clamp will be covered. This course will also address symptoms of an unsafe setup and apply these concepts to trim press operations.
Title: Everybody Is Involved in Die Setup
Date: February 26, 2019
The operators will learn the importance of die setup for success in die casting. Participants will be taught why fast efficient die setups are critical to allow manufacturing flexibility. The 8 types of waste and 5S concepts will also be introduced.
Title: Proper Care and Treatment of Dies During Production
Date: February 27, 2019
The operator will learn how to monitor and care for the die during production. Do's and dont's will be taught, to keep the dies in working condition. This course we will address how to recognize die wear based on inspecting the castings.
Title: Recognizing and Controlling Flow Defects
Date: February 28, 2019
The operator will learn how to recognize flow (surface) defects and what causes these types of defects. This course will address various operating parameters that impact flow defects, such as die temperature, die spray, cooling line flow rate, fill time and metal temperature. The operator will also learn corrective measures that can be taken to reduce and control flow defects, including preferred operating ranges for the various parameters.
Title: Recognizing and Controlling Porosity
Date: March 12, 2019
The operator will learn how to recognize gas and shrinkage porosity and what causes porosity. This course will cover the sources of gas porosity, such as trapped air, steam, and lubricant. After the causes and sources of porosity are presented, the operator will be informed of various corrective measures that can be taken to reduce and control porosity.
Title: Eliminating Solder and Flash Defects
Date: March 13, 2019
The operator will learn how what causes soldering and flash. The operating parameters and machine conditions that impact these two types of defects will be discussed. This course will also address die temperature, metal temperature, metal velocity and metal chemistry for soldering and tie bar load, linkage condition, impact pressure and die thermal balance for flash. Preferred operating ranges and machine conditions for eliminating solder and controlling flash will be presented.
Presented by Beau Glim and Paul Brancaleon
These webinars will take place at 12pm CST on the dates listed. The cost per webinar is $69 for Corporate Members, $99 for Individual Members or $119 for Non-Corporate Members. Signing up for all 11 parts of this series will also grant you access to these courses through the NADCA Online Education System, which allows you to view the recordings, pdf's and support material for a full year.
Learn more at the NADCA website page.
(If you liked this article you might also like this post on, "Die Casting Defects")
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