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Die Casting News

Die Casting vs. Sand Casting

Posted by Hill and Griffith Company on Dec 16, 2020 12:29:20 PM

What's the Difference?

Excerpt from the Thomas Register article by Christian Cavallo.

Casting metal is an ancient process now accomplished in a number of ways. It involves pouring molten metal into a mold where, upon cooling, the metal solidifies and conforms to the mold's shape. Casting allows manufacturers to create complex parts without the need for machining, which can be time-consuming and complicated; however, it is far from a simple, cut-and-dry technique in today's industry. There are many types of casting processes used in modern manufacturing, and each has its distinct benefits and disadvantages depending upon the desired characteristics of the end product. To better understand these unique processes, this article will explore two of the most widely used casting procedures: die casting and sand casting. A comparison of these two casting methods will give manufacturers a better idea of when to implement each process, and which one of these popular methods is best suited towards their application. This article will first explore each process, and then compare them to display why certain manufacturers choose one over the other.


Image credit: https://www.uddeholm.com/uk/en/applications/die-casting/

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Tags: Die Casting, Metal Casting, Die Casting Release Agent Application, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, Die Casting Porosity

Proper Application of Die Casting Lubricants Reduces Blisters

Posted by Hill and Griffith Company on Dec 3, 2020 10:51:55 AM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Blisters are another version of gas porosity, the gas just happens to be near the surface of the casting.
  • The trapped gas is under high pressure at the end of fill and the metal may shrink and squeeze it more.
  • When the casting is taken out of the die, and the die surface is no longer there to hold the casting shape, pressure from the trapped gas is able to push up a blister.

 

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Tags: Die Casting, Metal Casting, Die Casting Release Agent Application, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, Die Casting Porosity, NADCA Education

Science or Black Art?, Die Casting Lubricants

Posted by Hill and Griffith Company on May 29, 2019 7:20:21 PM

Article for North America Die Casting Association (NADCA) “Die Cast Engineer Magazine” 2007 by Tim Cowell, Technical Director for The Hill and Griffith Company

Introduction

Early on in the Die Cast Industry, die lubricants were usually a concoction of various compounds that the die caster had available to him.

1. He would create different mixtures and whatever yielded the best results for his specific application was what he used. Although much was learned from this trial and error type of evaluation, this method of die lubricant development was considered more of a “Black Art” than a science. Several decades later, there are some who still believe it. Over the years, die lubricant manufacturers and others have gone to great lengths to develop laboratory methods aimed at correlating a product’s performance in the lab with how it will perform in production, and yet there are still no standardized scientific methods within the industry for evaluating die lubricants. The only true test to determine the functionality of a new die lubricant is by its introduction to the production environment.


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Tags: Die Casting, Die Casting Release Agents, Metal Casting, Foundry Supply, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application

Die Casting Process Evaluation Checklist

Posted by Hill and Griffith Company on Jan 30, 2019 2:34:34 PM

Regular reviews and benchmarks are important for successful die casting process evaluations

The Hill and Griffith Company offers this helpful Die Casting Process Evaluation Form to submit your input.
 
On-site process surveys, casting defect investigations, product testing, tooling start-up programs, statistical process controls are available.
 
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Tags: Die Casting, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent Mold Coatings, Die Casting Process Evaluation

Kawasaki Robot Applying Die Casting Release Agent Video

Posted by Hill and Griffith Company on Oct 3, 2018 8:24:16 PM

Robotic machine tending can reduce machine overhead time.

Machine tending can be a simple, automated process of handling product to accommodate a machining process. However, reducing cycle time is crucial because tending a machine is not adding value to the product. Kawasaki is continually developing products to reduce cycle time and offer greater automation flexibility.

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Tags: Die Casting, Die Casting Release Agent Application

Checklist for Die Casting Process Evaluation

Posted by Hill and Griffith Company on Apr 19, 2017 4:40:15 PM

Regular reviews and benchmarks are important for successful die casting process evaluations

Hill and Griffith offers this helpful Die Casting Process Evaluation Form to submit your input.
 
Our sales representatives will respond with suggestions for further o n-site process surveys, casting defect investigations, product testing, tooling start-up programs, statistical process controls and much more. Also, lab facilities are available to provide testing upon request.
 
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Tags: Die Casting, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent Mold Coatings, Die Casting Process Evaluation

Largest high-pressure die casting machine in North America

Posted by Hill and Griffith Company on Apr 5, 2017 11:45:49 AM

Mercury Marine's new high-pressure die casting machine is now the largest in North America

FOND DU LAC, Wis., April 3, 2017 -- Mercury Marine, the world's leading manufacturer of recreational marine engines held an event today to officially announce commissioning of the largest high-pressure die casting machine in North America. Since 2009, Mercury Marine has now invested more than $800MM in R&D and manufacturing expansion at its Fond du Lac campus. 

This specific investment is a 4,500 ton Buhler-Prince machine.  Installation began late in 2016 and was just completed in late March 2017.

"This new machine positions us to make castings that no one else in the industry can do," said Mike Meyer, general manager Mercury Castings. "With this new machine, Mercury can make larger, lightweight structural components and reduce the overall weight of our engine by producing more efficient castings."

(Photo from Lake County, Mercury Marine Dealer)

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Tags: Die Casting, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent Mold Coatings

CONCOTE™ Permanent Mold Coatings

Posted by Hill and Griffith Company on Mar 31, 2017 1:53:13 PM

CONCOTE™ permanent mold coatings formulated with special refractories, binders, wetting agents, and preservatives. 

CONCOTE™ products provide a thin continuous film between the surface of the die and the castings.
 Features

  • Desired Surface Finish

  • Good Lubricity and Insulation

  • Good Release Properties

  • Prevents Premature Die Failure

  • Anti-Weld Properties

  • Easily Applied

Video from FLOW-3D, "Simulation of a low pressure die casting showing the filling temperature of a tire rim using FLOW-3D Cast."

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Tags: Die Casting, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Permanent Mold Coatings

The 2017 Die Casting Congress and Tabletop Needs Your Papers!

Posted by Hill and Griffith Company on Mar 22, 2017 4:21:27 PM

(This week's post comes from the March 8, 2017 by NADCA in Industry News. )

The Die Casting Congress and Tabletop is interested in your paper! Submit a proposal today to the NADCA Paper System!

NADCA would like to urge all metalcasters, researches and suppliers to submit papers on new technologies, procedures, equipment, and other innovations that contribute to productivity and quality enhancement in the metalcasting industry. Especially desired are papers relating practical experience and case studies from casting personnel, and papers on metalcasting management and marketing strategies.

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Here's an example of a technical article by Hill and Grifftih's Tim Cowell, Technical Director, published in 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 an 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 the complete article, "Resolving Adhesion Problems in Post Die Casting Operations," here.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Supplies, Die Casting Release Agent Application, 2017 Die Casting Congress, Die Casting Process Improvement, Die Casting Lubricants, Die Casting Process Videos

Die Casting Video of Fan Blade Manufacturing

Posted by Hill and Griffith Company on Mar 15, 2017 3:03:18 PM

(This week's post is a video that illustrates the typical spray nozzle arrangement for casting fan blades. )

From the die casting video published on Jul 9, 2013, "Die casting is a customized manufacturing method for producing OEM aluminum and zinc parts by forcing molten aluminum and zinc through high pressure into solid steel molds. These steel molds, called dies, are designed to create complicated layouts with a pinpoint accuracy and high volume production. Die cast parts can be precisely shaped, with rough or smooth material sides, and are optimized for a wide variety of attractive and serviceable finishes."

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants, Die Casting Process Videos

 


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