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Die Casting News

Basic Knowledge of Die Casting Tools and Molds

Posted by Hill and Griffith Company on Feb 10, 2021 4:47:41 PM

The mold determines the contours of a die cast part and affects its properties.

Excerpt from the Spotlight Metal March 2019 article by Isabell Page.

Die casting is a forming process for the mass production of, parts made from aluminum, magnesiumand their alloys. The casting process takes place in die casting machines which are divided in hot chamber and cold chamber die casting machines. The main difference is that in hot chamber casting machines the container with the molten metal is located inside the machine, while in the other case the container is placed outside the machine. In both types of machines, the molten metal is pressed from a casting chamber through one or more casting channels into the cavity of a permanent steel mold where it takes the shape of the die and solidifies. These die casting molds consist of two halves so the cast part can be removed from the mold. The feed-side mold half is mounted on a fixed plate on the rigid side of the die casting machine, while the ejector-side mold half is mounted on a movable plate placed on the other side. Before closing, the halves are sprayed with a release agent so that later the cast part can be easily released from the mold and the plates do not overheat. Depending on the size of cast parts, up to 300 casting cycles per hour can be carried out.

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Tags: Die Casting, Die Casting Release Agents, High Pressure Die Casting, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Global Casting Magazine

Eliminating Zinc Die Casting Defects

Posted by Hill and Griffith Company on Feb 3, 2021 5:29:45 PM

The Role of Alloys and Melting Processes in the Cause and Elimination of Zinc Die Casting Defects

Excerpt from the Spotlight Metal October 2013 article by John Titley.

Zinc alloy pressure die castings are selected because the process-material combination will manufacture precise net shape parts, which accept a wide variety of finishes. Very high-quality standards are achievable both consistently and cost-effectively over large production quantities.

This, coupled with the range of physical and mechanical properties available and the highly productive manufacturing process, has made the Zinc alloy die-cast part the first-choice material for a huge range of mass-produced components. This includes an extensive array of applications from electronics to locks, security and hardware for doors and windows, connectors and fittings for hydraulics and pneumatics, to decorative parts for the automotive industry. All of these applications utilize more than one of the properties available from Zinc alloy pressure die-castings.

However, this diversity carries a penalty the designer must consider when undertaking the new part manufacture. The need for high-quality decorative finishes invariably means the finishing criteria becomes more critical. This affects the cost and the prospect of higher reject rates must be taken into account.

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Tags: Die Casting, Die Casting Release Agents, High Pressure Die Casting, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Global Casting Magazine

Methods and Measures to Reduce the Solder Defect of Die Casting Surfaces

Posted by Hill and Griffith Company on Apr 22, 2020 9:15:15 PM

Excerpt from the January 2020 Issue of Global Casting Magazine

The solder defect in die casting affects surface quality and strength, especially in castings with a high seal requirement. The defect could lead to leakage that would mean more wasted cost (Fig 1.). Four aspects of soldering were analyzed, including:

  • chemical principle
  • mold structure
  • release agent
  • die casting process

For example, JAC die casting company in Suzhou, China, supplies parts to customers that don’t allow solder to be visible to the naked eye. For a German company in Shandong, China, which produces automobile parts, the solder defect area can be no more than 20 x 20 mm. Another company which produces parts with thin walls and high temperature pouring, have found it is at higher risk for solder defects.

What factors cause the solder defect? What’s the physical or chemical change between the liquid aluminum and hot iron mold? This article will share the results of a study on this defect based on the chemical principle, mold structure, release agent and die casting process.

Interfacial reaction is a series of chemical interactions that occur between the interface of two phases, according to chemical type, content, status and properties.

Solder defect is started by the chemical and physic reaction due to the strong affinity in Fe-Al. A new compound is created when the mold and liquid Al connect closely. The higher the temperature, the more intense the thermal vibration of the atoms, causing the solder ratio to rise and the corrosion of the mold to increase, until finally, it causes the solder area. When polished, the surface containing a thin nitride layer will be destroyed, causing worse cycle. Some data in the study showed that the affinity of Fe-Al will become more serious as the Fe element is decreased, creating more solder.

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

5 Steps to Identify Casting Defects

Posted by Hill and Griffith Company on Aug 21, 2019 2:38:22 PM

Excerpt from the article in Global Casting magazine's September 2018 issue

The procedure of identifying, diagnosing and minimizing or eliminating crucial casting defects is important for a foundry to run in a low-cost, and high-efficiency mode. It can disprove incorrect conventional wisdom and show that unexpected methods are actually the best way to move forward. To do this, there are three keys to remember:

1. Focus on identifying a casting defect on the basis of its appearance.

2. Be aware of the interactive nature of foundry processes and variables.

3. Use rigorous experimental design methods to study complex causes of defects.

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Tags: Die Casting, Die Casting Plunger Lubricants, Die Casting Lubricants, Die Casting Defects, NADCA, Global Casting Magazine

 


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