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Die Casting News

Pushing for Larger-Dimension Die Castings

Posted by Hill and Griffith Company on Feb 24, 2021 4:03:33 PM

Lightweight vehicle designs need high volumes of complex cast parts, prompting a wave of projects for large pressure die casting machines.

Excerpt from the Foundry Management & Technology November 2015 article by Robert Brooks.

Walker Die Casting, a Lewisburg, TN, producer of aluminum components for automotive and truck manufacturing, has ordered a 4,500-ton cold-chamber die casting machine from HPM North America to be delivered in 2017. According to the contractor, it is the largest cold-chamber machine it has produced to-date in North America. But, that distinction may not last for long.

There is an outbreak of demand in North America for new die casting capacity on that scale, machines sized to produce a range of highly engineered parts in aluminum alloys. Its demand was prompted by motor vehicle manufacturers working on new production programs keyed to lighter vehicles, with lighter component parts for powertrains, drivetrains, and structural systems.

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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, Foundry Management & Technology magazine

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

Relevance of Die Casting Release Agents

Posted by Hill and Griffith Company on Jan 20, 2021 4:34:32 PM

Excerpt from the Spotlight Metal December 2019 article by Nicole Kareta.

The use of die casting release agents represents an essential process step in the production of cast parts, as the so-called mold release agent prevents components from sticking to the mold or the metal from being soldered to the mold. What else is worth knowing about die casting release agents?

As a rule, release agents are sprayed onto the wall of the die casting mold. This separates the metal from the mold and also simplifies the de-molding of the casting. In addition, die casting release agents offer numerous other functions and advantages which have a positive influence on the entire production process:

  • Improved flow of molten metal
  • Easy removal thanks to homogeneous coating
  • Good lubrication of moving parts
  • Improvement of economic efficiency due to lower material requirements
  • Shortened cycle time due to cooling properties
  • Continuously high product quality
  • Reduced scrap rates
  • Increased mold life
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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, SpotLightMetal.com

Using PVD Coatings to Reduce Die Casting Costs

Posted by Hill and Griffith Company on Jan 13, 2021 4:49:57 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 Foundry Management & Technology February 2020 article by David Bell, Viktor Khominich, and Steve Midson.

Die casting often is the lowest-cost method to produce castings, especially when large volumes of components are required. However, the reusable steel dies used in die casting 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. Using PVD coatings to address these mechanisms can extend die life, reduce die maintenance, and so minimize overall manufacturing costs.

Die casting 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, High Pressure Die Casting, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Foundry Management & Technology magazine

Combining Toughness, Thermal Resistance in HPDC Die Steel

Posted by Hill and Griffith Company on Jan 7, 2021 10:32:01 AM

New automotive casting objectives highlight the deficiencies in standard tooling materials, but an alternative promises quality, lower cost, longer tool life, and more

Excerpt from the Foundry Management & Technology November 2019 article

The difficulties of casting high-volume automotive parts are well established, and those issues become more critical in production of critically engineered parts, such as the increasing volume of parts produced by high-pressure die casting (HPDC.) Three experts in hot-work production addressed the issues recently in a white paper for Uddeholm AB's newly developed Uddeholm Dievar 25 Joules tool steel for die manufacturing. It gives "the perfect balance between toughness and heat-checking" for HPDC, and other applications, they claim.

Most dies used by foundries, diecasters, and OEMs are formed in AISI H13 or H11, but the Uddeholm experts raise the concern that the die-related problems of HPDC powertrain and transmission castings have not changed in decades, and may be more acute with the advent of production for hybrid and electric vehicle castings.

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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, Die Casting Engineer

Review of Die Cast Plunger Lubrication System Patent

Posted by Hill and Griffith Company on Feb 22, 2017 2:11:49 PM

(This week's post is a review of a die casting plunger lubricant patent US 5076343 A in order to learn more about the application and technology.)

Die cast plunger lubrication system patent

ABSTRACT
A lubrication system for the plunger of a die cast machine is disclosed that does not require a timing mechanism or an additional pressure source for the lubricant. The forward stroke of a lube piston is used to force lubricant out of a lubrication chamber in the plunger through a passageway to the outer surface of the plunger by decreasing the volume of the lubrication chamber. A spring within the plunger's lubrication chamber is used to retract the piston and thereby increase the volume of the lubrication chamber. The relatively low pressure during this retraction stroke allows lubricant to flow from a lubricant tank into the lubrication chamber for distribution during the next forward stroke of the plunger.

 

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Tags: Die Casting, Die Casting Release Agents, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Die Casting Process Improvement, Die Casting Lubricants

Die Casting Lubricants

Posted by Hill and Griffith Company on Feb 16, 2017 9:35:35 AM

Cost Effective, Innovative and Environmentally Sound Non-ferrous Die Casting Products


Die Casting, Squeeze Casting & Permanent Mold Lubricant products that represent the latest in technology and ongoing research in die casting, squeeze casting and permanent mold-release techniques that will enhance your competitiveness. Our Die Casting Lubricants promote cleaner dies while increasing productivity. Custom blended die casting lubricants for your specific application include: Diluco™ 100 Series water-base, 300 Series for squeeze casting, Concote™ low pressure die casting or permanent mold coating and Plunger Lube™ water-based for cleaner and more efficient cooling.

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates, Die Casting Lubricants

Aluminum Characteristics by Alloy

Posted by Hill and Griffith Company on Feb 8, 2017 3:55:50 PM

(Today's post is a review of an article that was published in the Jul/Aug 2016 issue of METALCASTING DESIGN & PURCHASING. You can read the entire article "Aluminum Characteristics by Alloy" here.)

Inside the aluminum family, the various alloys exhibit marked and unique manufacturing characteristics that distinguish themselves. Generally, cast aluminum should be used for applications that require lower weight and structure without necessarily needing high strength at elevated temperatures. To help you choose the best fit, the following breaks down the castability, machinability, finishing tendencies, weldability and corrosion resistance of common alumi­num casting alloys (Table 1).

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates

The Science of Successfully Anodizing Die Castings Substrates

Posted by Hill and Griffith Company on Feb 1, 2017 2:46:46 PM

(Today's post is the Conclusion of an article, "The science of successfully anodizing die castings substrates," which is a review of several questions received by PRODUCTS FINISHING Magazine. It was published by www.aluminumtoday.com. You can download the full article here or use this link.)

Conclusion
There is no ‘trick’ to anodizing complex alloys; there are ways, grounded in scientific reason, to approach challenges. 

 

Fig 5a and 5b: Schematic of the walls of the anodic oxide at the junction of three anodic oxide cells. An entire cell is bracketed with pink dotted lines; the central pore appears gray with repulsive forces represented by a single sphere. The fcc aluminium structure is at the bottom of the schematic with the current bias represented by bold green arrows. The forming tetrahedral structure (5a and 5b) exhibits the primary oxidation reaction at the interface between the fcc and the electrolyte in the pore by the presence of oxygen atoms on the tetrahedral structure.

The schematic on the right (5b) shows non-aluminium ions (copper colored) diffusing from the fcc lattice, through the tetrahedral anodic oxide network, into the central pore where it will be carried into the electrolyte.

Note how the copper atoms ‘pile up’ at the fcc-tetrahedral interface. This is due to the structural/compositional mismatch between the aluminium and the anodic oxide

 

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Tags: Die Casting, Die Casting Release Agents, Die Casting Adhesion Solutions, Mechanical Interlocking Adhesion, Die Casting Adhesion Prevention, Gravity Die Casting, High Pressure Die Casting, Die Casting Plunger Lubricants, Die Casting Supplies, Die Casting Release Agent Application, Magnesium Die Casting, 2017 Die Casting Congress, Die Casting Process Improvement, Anodizing Die Castings Substrates

 


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