After tackling the 3D printer, material and design, there's still one challenge left for Exco Engineering: convincing customers.

Article Excerpt from the December 2019 Modern Machine Shop issue

Die casting is a particularly harsh operation. The process involves forcing molten metal into a mold cavity at high pressure, and is commonly used to make automotive parts such as engine blocks, wheels and engine cradles. The tooling that produces these parts must be durable, and buyers are not likely to trust a new process easily. In other words, die cast tooling is not an obvious place to experiment — but the challenge of the process makes it exactly the kind of application that is ideal for testing the limits of metal 3D printing.

This is what Exco Engineering (located in Toronto) has done over the last four years. In an initiative led by Wes Byleveld, now director of additive manufacturing, the company has not only proven that 3D printed tooling can withstand the die cast process, but that it also provides benefits to that process in the form of better cooling, reduced cycle time and longer tool life.

Read More

Tags: Die Casting, Metal Casting, Permanent Mold, Die Casting Adhesion Solutions, High Pressure Die Casting, Die Casting Awards, Magnesium Die Casting, Modern Machine Shop

High Pressure Die Casting

Excerpt from the Encyclopedia of Materials: Science and Technology 2001

High-pressure die casting is a process in which molten metal is forced under pressure into a securely locked metal die cavity, where it is held by a powerful press until the metal solidifies. After solidification of the metal, the die is unlocked, opened, and the casting ejected. After removal of the casting, the die is closed and locked again for the next cycle. The injection of metal into the die cavity is completed in a fraction of a second. Often, while the molten metal is still held in the die, extremely high pressure is applied (called intensification pressure). This high pressure compresses any gas entrapped in the metal and feeds additional metal into the cavity to compensate for the shrinkage of the metal as it solidifies.

Two types of systems are used for injecting the molten metal into the die. The hot chamber system is used with metals such as zinc, magnesium, and lead. The injection system of a hot chamber machine is immersed in the molten metal bath of the melting furnace. As the shot plunger moves, it forces metal through the nozzle and into the die.

Read More

Tags: Die Casting, Metal Casting, Permanent Mold, Die Casting Adhesion Solutions, High Pressure Die Casting, Die Casting Awards, Magnesium Die Casting

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 a die casting 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 More

Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

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 a die casting 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 More

Tags: Die Casting, Metal Casting, Die Casting Adhesion Solutions, Die Casting Awards, Magnesium Die Casting

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.

 

Read More

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

(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).

 

Read More

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

(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

 

Read More

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

Specialty Industrial Lubricants

The Hill and Griffith Company offers Griflube Hydraulic Fluids that are biodegradable, fire-resistant and high-pressure hydraulic fluid under its new GRIFLUBE® line of specialty industrial lubricants engineered for precision hydraulic fluid applications. The new line of products includes the Aquatech FR 200 premium water glycol, the new biodegradable Bio-Syn fire resistant fluid, Gear Oil EP industrial gear lubricants, Premier AW (Anti-Wear) hydraulic and lubricating oils, Premier R&O hydraulic circulating oils and Slide-Way lubricants.

Read More

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

September 18-20, 2017, Atlanta, GA

 

The 2017 Die Casting Congress & Tabletop will be held September 18-20, 2017, at the Atlanta Convention Center at the Americasmart in Atlanta, GA. This event will include three days of Congress sessions. The Congress session schedule for 2017 is adjusted to create more time for those attending sessions to also attend the show exhibits. 

 

Read More

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

Tim Cowell, Technical Director, The Hill and Griffith Company
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 a die casting adhesion problems. 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 More

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, Die Casting Process Improvement