<img alt="" src="https://secure.hims1nice.com/150891.png" style="display:none;">

Die Casting News

Find Out How Spray and Lubricant Affect Die Casting Quality

Posted by Hill and Griffith Company on Nov 11, 2020 2:54:10 PM

Register for Two Upcoming NADCA-Sponsored Webinars

This series will look at, die sprays, plunger lubricants and their effect on casting quality. With an in-depth discussion of both die and plunger lubricants we will look at their chemistry, function, application and effects on casting production and quality. The course will review pulse spray, its application and results at two production facilities. Hydrostatic spray will also be reviewed with application examples and use of hydrostatic spray.

Read More

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

Simulation of High Pressure Die Casting Process for Identifying and Minimizing Defects

Posted by Hill and Griffith Company on Oct 7, 2020 4:56:12 PM

Excerpt from the August 2015 article from the International Journal of Engineering Research & Technology by A. Advekar, Y. Arunkumar, and M.S. Srinath

Introduction

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

Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Journal of Engineering Research and Technology

Top 3 Remedies for Defects Caused by Die Casting

Posted by Hill and Griffith Company on Sep 29, 2020 8:38:24 PM

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

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 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.

Read More

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.

 

Read More

Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management

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.

 

Read More

Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management

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.

 

Read More

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 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.

Read More

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.

 

Read More

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

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.

Read More

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

 


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend metalworking fluids that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy." Metalworking fluids, Die casting and squeeze casting lubricants, Casting operations products, 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, and Way oil knuckle lubes.

Contact us for Product Samples

Hill and Griffith Customer Service

Technical Services & Support

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

Arrange a Metalworking Solutions Visit

Bulletins and Technical Papers for Metalworking Products

Subscribe to Die Casting News

Die Casting News

Follow Us

Diecasting News Categories

see all