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Die Casting News

Is 3D Printed Tooling a Solution for Die Casting?

Posted by Hill and Griffith Company on Mar 24, 2021 5:03:24 PM

After tackling the 3D printer, material and design, there's still one challenge left for Exco Engineering: convincing customers.

Article Excerpt from the December 2019 Modern Machine Shop issue

Die casting is a particularly harsh operation. The process involves forcing molten metal into a mold cavity at high pressure, and is commonly used to make automotive parts such as engine blocks, wheels and engine cradles. The tooling that produces these parts must be durable, and buyers are not likely to trust a new process easily. In other words, die cast tooling is not an obvious place to experiment — but the challenge of the process makes it exactly the kind of application that is ideal for testing the limits of metal 3D printing.

This is what Exco Engineering (located in Toronto) has done over the last four years. In an initiative led by Wes Byleveld, now director of additive manufacturing, the company has not only proven that 3D printed tooling can withstand the die cast process, but that it also provides benefits to that process in the form of better cooling, reduced cycle time and longer tool life.

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Tags: Die Casting, Metal Casting, Permanent Mold, Die Casting Adhesion Solutions, High Pressure Die Casting, Die Casting Awards, Magnesium Die Casting, Modern Machine Shop

Die Casting - Permanent Mold

Posted by Hill and Griffith Company on Mar 17, 2021 5:01:57 PM

High Pressure Die Casting

Excerpt from the Encyclopedia of Materials: Science and Technology 2001

High-pressure die casting is a process in which molten metal is forced under pressure into a securely locked metal die cavity, where it is held by a powerful press until the metal solidifies. After solidification of the metal, the die is unlocked, opened, and the casting ejected. After removal of the casting, the die is closed and locked again for the next cycle. The injection of metal into the die cavity is completed in a fraction of a second. Often, while the molten metal is still held in the die, extremely high pressure is applied (called intensification pressure). This high pressure compresses any gas entrapped in the metal and feeds additional metal into the cavity to compensate for the shrinkage of the metal as it solidifies.

Two types of systems are used for injecting the molten metal into the die. The hot chamber system is used with metals such as zinc, magnesium, and lead. The injection system of a hot chamber machine is immersed in the molten metal bath of the melting furnace. As the shot plunger moves, it forces metal through the nozzle and into the die.

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Tags: Die Casting, Metal Casting, Permanent Mold, Die Casting Adhesion Solutions, High Pressure Die Casting, Die Casting Awards, Magnesium Die Casting

Resolving Adhesion Problems - Post Die Casting Operations

Posted by Hill and Griffith Company on Mar 10, 2021 9:36:12 PM

Introduction

In the Die Casting Industry, many of the castings manufactured undergo secondary operations incorporating the use of paints, adhesives and other polymers such as RTV (Room Temperature Vulcanization).  The application of these types of materials requires the polymer to bond to the metal substrate (surface) of the casting.  When this bond fails, it is considered to be a die casting adhesion problem. For the die caster, this can be a very costly problem; therefore, it is imperative that it be solved quickly.

To gain a better understanding of the problem and its potential solution, the following points will be discussed. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem
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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Post Die Casting Operations - Resolving Adhesion Problems

Posted by Hill and Griffith Company on Nov 15, 2018 3:32:25 PM

Introduction

In the Die Casting Industry, many of the castings manufactured undergo secondary operations incorporating the use of paints, adhesives and other polymers such as RTV (Room Temperature Vulcanization).  The application of these types of materials requires the polymer to bond to the metal substrate (surface) of the casting.  When this bond fails, it is considered to be a die casting adhesion problem. For the die caster, this can be a very costly problem; therefore, it is imperative that it be solved quickly.

To gain a better understanding of the problem and its potential solution, the following points will be discussed. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem
Read More

Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Is 2017 The Year for 5S - Die Casting Process Improvement?

Posted by Hill and Griffith Company on Dec 28, 2016 9:59:21 AM

Thanks to the North American Die Casting Association for giving us a possible Die Casting Process Improvement New Year's Resolution.

1. Sort: Remove all unnecessary items
2. Set in Order: Arrange items too be used
3. Shine: Clean workplace. Floors, trash, machine, etc.
4. Standardize: Simplify job and content.
5. Sustain: Maintain 5S habit

And some like to add a sixth
6.Safety: Keep Safety in mind during all these steps.


 

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting, Die Casting Process Improvement, Die Casting Congress West

NADCA Die Casting Congress West

Posted by Hill and Griffith Company on Dec 15, 2016 5:15:25 PM

NADCA is excited to announce the first ever Die Casting Congress West on January 18-19, 2017 at the Hilton Long Beach.  The Congress will feature technology highlights of our Congress in Columbus earlier this fall. The event will kick off with a cocktail reception on January 18 and lead into a full day of presentations on January 19.  

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting, Die Casting Congress West

NADCA Structural Die Casting Webinar Series

Posted by Hill and Griffith Company on Dec 7, 2016 1:48:18 PM

Complimentary NADCA Webinar Series
Register: http://www.diecastingdesign.org/webinar

This webinar series is designed to inform the OEM about the benefits and capabilities of structural diecastings and their applications. This new and growing segment of the high pressure die casting industry provides die cast components for critical applications since they are high in ductility, and are also weldable and heat treatable due to extremely low porosity levels. Steve Udvardy, North American Die Casting Association - http://www.diecasting.org - Director of Research, Education & Technology will be presenting a three part webinar series.

(Illustration of the typical die casting machine and consumables provided by the Hill and Grifftih Company.)

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting, structural die casting

Die Casting Release and Plunger Lube Application to Reduce Porosity

Posted by Hill and Griffith Company on Nov 30, 2016 3:52:22 PM

th(This week's post is the combination of a review of the technical paper "Analyze of the Possible Causes of Porosity Type Defects in Aluminum High-pressure Diecast Parts" by Ferencz Peti and Lucian Grama; and 3D scanned images of die casting porosity from Exact Metrology thanks to Amy Cupp.)

Abstract

The most common defect that appears in castings is the porosity type of defect, which can be gas porosity, shrinkage porosity or leaker.

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Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Resolving Adhesion Problems in Post Die Casting Operations

Posted by Hill and Griffith Company on Nov 17, 2016 4:51:02 PM

Tim Cowell, Technical Director, The Hill and Griffith Company
Published in the Sept. 2014 issue of DIE CASTING ENGINEER, official publication of the North American Die Casting Association

Introduction

In the Die Casting Industry, many of the castings manufactured undergo secondary operations incorporating the use of paints, adhesives and other polymers such as RTV (Room Temperature Vulcanization).  The application of these types of materials requires the polymer to bond to the metal substrate (surface) of the casting.  When this bond fails, it is considered to be a die casting adhesion problem. For the die caster, this can be a very costly problem; therefore, it is imperative that it be solved quickly.

To gain a better understanding of the problem and its potential solution, the following points will be discussed. 

  1. What creates Adhesion?
  2. What prevents Adhesion?
  3. Assessing the Problem
  4. Solving the Problem
Read More

Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

Magnesium Die Cast Liftgate Cuts Weight, Adds Value

Posted by Hill and Griffith Company on Nov 9, 2016 8:48:49 AM

Meridian Lightweight Technologies and Fiat Chrysler Automobiles teamed up on this year's award winning casting - this first high volume application of the structural magnesium die casting. 

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Tags: Die Casting, Metal Casting, Die Casting Awards, Magnesium Die Casting

 


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