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Die Casting News

Die-Release and Die-Spray Technologies Improve Productivity

Posted by Hill and Griffith Company on Jun 24, 2020 1:34:31 PM

As lightweight automotive design fuels more diecasting applications, faster die-spraying is cutting cycle times, and more uniform adhesion is improving process reliability.

Excerpt from the June 2020 article from Foundry Management & Technology

Cost optimization and improved productivity and product quality are driving die casting strategies, particularly in the face of global competition and the need to produce more complex components. Automotive design and manufacturing are prompting to die casters to take on more complex, lightweight, components for powertrain, chassis, and structural parts. In turn, this has guided investments in larger high-pressure die casting machines and more expensive tooling, which has manufacturers seeking to improve productivity, process reliability, and product quality, and to extend die service.

The main purpose of a die-release agent is to allow clean part release and provide a release film that minimizes die soldering, and uniform coverage is critical to both process reliability and the finished product quality.  Standard water-based lubricants evaporate in contact with a hot steel die, leaving a lubricant coating. This is a critical stage, because too much lubricant means liquid cannot evaporate quickly enough when molten metal is injected; and too little lubricant may result in poor material flow (i.e., "die soldering"), and then causing surface defects and porosity that reduce finished product quality.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Release Agents for Die Casting, Aluminum Die Casting Process, Die Casting Defects, Die Casting Mold Lubricants, Die Casting Lubricant, Aluminum Die Casting, Die Casting Lubrication and Application, die casting lubricant management, Foundry Management & Technology magazine

Predicting Castability for Thin-Walled HPDC Parts

Posted by Hill and Griffith Company on Jun 17, 2020 2:43:30 PM

Current simulation tools account for the physics of fluidity, and should be capable of predicting castability too. Investigating thermal resistance shot sleeve heat loss effect of conventional HTC values.

Excerpt from the December 2014 article from Foundry Management & Technology by R. Bhola and S. Chandra

The term "thin-wall castings" for the HPDC process has been investigated for well over two decades.  However, the perception of what is considered a thin-walled part has changed over the years and continues to change.  Historically, 3-mm wall thickness was considered a thin HPDC part and that number decreased over the years to 2 mm, and further to 1 mm. Currently, there is a push for even thinner walled parts in the electronics industry, with thickness demands as low as 0.6 mm.  The automotive industry has been looking to make ultra large castings (ULC) using various processes, including semi-solid, permanent mold, and HPDC processes, with target thickness in the range of 1 to 2 mm[2].

Thin-walled parts are difficult to cast because the melt cools rapidly upon contact with the relatively cold die steel and can solidify quickly before die filling is complete.  The distance a given molten material travels before it freezes and stops moving is commonly referred to as "fluidity".  The dominant variables affecting fluidity are: thermophysical properties of the melt; the temperature of the melt above liquidus (superheat); and mold coating release agent[3,4].  Much of this work on quantifying fluidity was based on experiments under low pressures, generally not exceeding 15 psi to force the liquid metal through a passage. 

Further, die temperature and the heat-transfer coefficient at the die surface do not seem to be considered properties that define fluidity, though Dewhirst[4] acknowledged that the heat-transfer coefficient at the mold surface does play a significant role in the measured flow lengths for a given alloy type under given test conditions.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Release Agents for Die Casting, Aluminum Die Casting Process, Die Casting Defects, Die Casting Mold Lubricants, Die Casting Lubricant, Aluminum Die Casting, Die Casting Lubrication and Application, die casting lubricant management, Foundry Management & Technology magazine

The Benefits of Semi-Solid Casting for Aluminum Alloys

Posted by Hill and Griffith Company on Oct 16, 2019 7:00:00 AM

Excerpt from the August 2015 issue of Foundry Management & Technology by Pascal Côté, Giovanni Pucella, and Steve Midson

The Swirled Enthalpy Equilibration Device (SEED) represents a new possibility for high-volume, high-productivity, thin-walled casting production. Production process advantages:

  • Minimal residual porosity
  • Increased die-filling speed
  • Extended tool life
  • Minimal turbulence

Semi-solid metalcasting (SSM) was developed in the 1970s and became a commercial process for thixocasting (billet re-heating) in the 1990s, and for rheocasting (generating the semi-solid slurry directly from the liquid) in the 2000s. However, despite significant technical and economic advantages, as pointed out recently by Jorstad(1), SSM has never advanced to become the major metalcasting process anticipated by so many early investigators. Certainly, there have been a number of obstacles to the commercialization of SSM, such as the original thixocasting process being relatively expensive, early rheocasting processes not being fully competitive, along with improvements made to already-facilitated competing casting processes (squeeze casting, conventional die casting, and high vacuum die casting.)

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Foundry Management & Technology magazine

 


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