For the last 46 years, NADCA has sponsored its International Die Casting Design Competition to showcase outstanding die cast designs while acknowledging the continuous contribution die casters provide to the manufacturing industry. As die castings become more complex, higher quality, lower cost, and more unique, it becomes important for die casters to be involved in the process early in the product’s design phase. A die casting is not a machined part, sand casting, or an extrusion. It is critical for die casters to effectively communicate to the designer requirements to make a quality casting. The winners of the 2020 International Die Casting Competition have exhibited a close relationship with their customer to produce castings that have a complex design, high quality, and ingenuity. These castings often expand the market for die casting and reduce the cost of the part compared to the previous manufacturing method.Read More
Die Casting News
Excerpt from the June 2007 TotalMateria.com article.
Squeeze casting as liquid-metal forging is a process by which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press.
The applied pressure and instant contact of the molten metal with the die surface produce a rapid heat transfer condition that yields a pore-free fine-grain casting with mechanical properties approaching those of a wrought product. The squeeze casting process is easily automated to produce near-net to net shape high-quality components.
The process was introduced in the United States in 1960 and has since gained widespread acceptance within the nonferrous casting industry. Aluminum, magnesium, and copper alloy components are readily manufactured using this process. Several ferrous components with relatively simple geometry, for example, nickel hard-crusher wheel inserts-have also been manufactured by the squeeze casting process.Read More
Excerpt from the August 2015 article from the International Journal of Engineering Research & Technology by A. Advekar, Y. Arunkumar, and M.S. Srinath
High-pressure die-casting (HPDC) process is widely used to manufacture a large variety of products with high dimensional accuracy and productivities. It has a much faster production rate in comparison to other methods and it is an economical and efficient method for producing components with low surface roughness and high-dimensional accuracy. All major aluminum automotive components can be processed with this technology. In this process, the metal is injected into the die at high speeds (30–100 m/s and typically 40–60 m/s for aluminum alloys) and under high pressure through complex gate and runner systems.
The mechanical properties of a die-cast product are principally related to the die temperature, the metal velocity at the gate, and the applied casting pressure. Die casting is a manufacturing process that produces geometrically complex metal parts through reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum). The differences between these machines will be detailed in the sections on equipment and tooling. However, in both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part, called the casting.Read More
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Excerpt from the Manufacturing Technology Insights August 2020 article
The most common defects in die casting are caused due to misruns and cold shuts. Below are three remedies for common defects caused by die casting.
Fremont, CA: The die casting process forces molten metal into a cavity at high pressure and is commonly used to make automative parts like engine blocks, wheels, and engine chassis. The tooling producing these parts must be durable. Buyers are not likely to trust a new process easily. Die cast tooling is not a prominent place to experiment, but the challenge of the method makes it precisely the kind of application that is ideal for testing the limits of metal 3D printing.Read More
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.Read More
Excerpt from the January 2010 issue of Metallurgical Science & Technology by Giulio Timelli
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.
Excerpt from the March 2017 issue of International Journal of Engineering Research and Application by Vaibhav Ingle and Madhukar Sorte
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.
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.
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.Read More
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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