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Die Casting News

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.

 

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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.

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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

Reduction of Blowholes in Aluminum High Pressure Die Casting Machines

Posted by Hill and Griffith Company on Aug 12, 2020 8:43:40 PM

Excerpt from the August 2018 article from the International Journal of Engineering & Technology by P. Nagasankar, et.al.

Abstract

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defects found through why-why analysis technique. Process capability of current high pressure die cast manufacturing is checked. The current problem of blowhole defects are solved by making an improvement in design of the die inserts. In-gate directions are changed to obtain modified improved flow patterns. Using magma flow simulation software, existing and modified design is compared. It is found that modified design shows superior results, and using this, the defect of blowholes is minimized satisfactory.

 

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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

High Integrity Die Casting Processes

Posted by Hill and Griffith Company on Aug 5, 2020 8:46:06 PM

Defects in High Pressure Die Casting Processes

Excerpt from the instructional book by Edward J. Vinarcik

11.1 Introduction

Casting processes are inherently complex due to the phase transformation from liquid to solid metal, which creates all geometric features as well as material properties. With such an intricate process, many potential defects may result. Potential defects related ot high integriy die casting are presented in this chapter. Defects encountered in conventional die casting will be introduced but will not be discussed in detail, as several texts are available that examine these issues. Defects unique to high integrity die casting processes will be discussed in greater detail.

11.2. Conventional Die Casting Defects

Many potential defects commonly found in conventional die casting can also occur in hight ingegrity die casting. often these defects are avoidable if basic guidelines are followed related to component design, equipment selection, die design, process design, raw material quality, process control, die maintenance, equipment upkeep, and material handling. Conventional die casting defects can be divided into three categories: surface defects, internal defects, and dimensional defects. Each category will be discussed separately below.

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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

Using PVD Coatings to Reduce Diecasting Costs

Posted by Hill and Griffith Company on Jul 22, 2020 12:44:02 PM

Coating can address heat checking, excessive soldering, and erosion, to extend die life, reduce die maintenance, and minimize overall manufacturing costs.

Excerpt from the article in the February 2020 issue of Foundry Management & Technology by David Bell, Viktor Khominich and Steve Midson

Diecasting often is the lowest-cost method to produce castings, especially when large volumes of components are required. However, the reusable steel dies used in diecasting typically are expensive, and may be a significant portion of overall production costs. Therefore, extending die life can have a significant effect on reducing production costs. Dies typically fail for one of three reasons: heat checking, excessive soldering, or erosion, and using PVD coatings to address these mechanisms can extend die life, reduce die maintenance, and so minimize overall manufacturing costs.

Diecasting involves injecting liquid metal into a reusable steel die at extremely high rates (gates speeds between 80-250 ft/sec, cavity fill times of 0.05-0.2 sec) and high pressures (6,000 to 15,000 psi). Due to these aggressive conditions, soldering (sticking) of the castings to the die can be a problem, and to minimize soldering, casters use a water-based organic lubricant (basically a parting agent) sprayed onto the die face before each shot. The lubricant forms a barrier between the casting and the steel die to minimize soldering and sticking.

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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

 


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