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Die Casting News

Is 3D Printed Tooling a Solution for Die Casting?

Posted by Hill and Griffith Company on Mar 24, 2021 5:03:24 PM

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.

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

Die Casting - Permanent Mold

Posted by Hill and Griffith Company on Mar 17, 2021 5:01:57 PM

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.

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

Resolving Adhesion Problems - Post Die Casting Operations

Posted by Hill and Griffith Company on Mar 10, 2021 9:36:12 PM

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

Die Casting vs. Sand Casting

Posted by Hill and Griffith Company on Dec 16, 2020 12:29:20 PM

What's the Difference?

Excerpt from the Thomas Register article by Christian Cavallo.

Casting metal is an ancient process now accomplished in a number of ways. It involves pouring molten metal into a mold where, upon cooling, the metal solidifies and conforms to the mold's shape. Casting allows manufacturers to create complex parts without the need for machining, which can be time-consuming and complicated; however, it is far from a simple, cut-and-dry technique in today's industry. There are many types of casting processes used in modern manufacturing, and each has its distinct benefits and disadvantages depending upon the desired characteristics of the end product. To better understand these unique processes, this article will explore two of the most widely used casting procedures: die casting and sand casting. A comparison of these two casting methods will give manufacturers a better idea of when to implement each process, and which one of these popular methods is best suited towards their application. This article will first explore each process, and then compare them to display why certain manufacturers choose one over the other.


Image credit: https://www.uddeholm.com/uk/en/applications/die-casting/

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Tags: Die Casting, Metal Casting, Die Casting Release Agent Application, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, Die Casting Porosity

Proper Application of Die Casting Lubricants Reduces Blisters

Posted by Hill and Griffith Company on Dec 3, 2020 10:51:55 AM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Blisters are another version of gas porosity, the gas just happens to be near the surface of the casting.
  • The trapped gas is under high pressure at the end of fill and the metal may shrink and squeeze it more.
  • When the casting is taken out of the die, and the die surface is no longer there to hold the casting shape, pressure from the trapped gas is able to push up a blister.

 

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Tags: Die Casting, Metal Casting, Die Casting Release Agent Application, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, Die Casting Porosity, NADCA Education

Video News Update: Die Casting Lubricants, Applications and Effects

Posted by Hill and Griffith Company on Feb 12, 2020 11:20:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Casting Lubricants, Application and Effects. The application and background of pulse spray is reviewed. Actual Case Studies are reviewed on the application of pulse spray in two die casting facilities. Electrostatic Spray - The basic principles of electrostatic spray are reviewed. The application of electrostatic spray is demonstrated. Plunger Lubrication - The function, chemistry and application of plunger lubricants are reviewed. This webinar also reviews the effect on quality of die cast parts if the plunger application is not closely controlled.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Product Design for Die Casting

Posted by Hill and Griffith Company on Jan 15, 2020 8:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Product Design for Die Casting. This initial webinar in the series will provide an introduction and overview of the die casting process.


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Tags: Die Casting, Metal Casting, Squeeze Casting Release Agents, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Die Casting Spray

Posted by Hill and Griffith Company on Dec 18, 2019 3:42:21 PM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Die Spray. Die spray is essential for applying release agent to the die. It is also used to help control the die temperature and temperature distribution. This course will give an overview of the literature addressing spray. The overview will finish with applications and areas to explore in your own plant to reduce spray use and casting defects. The following topics ware addressed in this course: Die Spray, Flow rate, Spray angle, Time, Die temperature, Effects of die spray and Strategies for improved die spray.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

Video News Update: Mechanical Maintenance & Evolution of Die Casting Machines

Posted by Hill and Griffith Company on Nov 13, 2019 4:42:41 PM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Mechanical Maintenance & Evaluation of Die Cast Machines: Die Casting Machine Primary Mechanical Structures. The first in the Mechanical Maintenance & Evaluation of Die Cast Machines series covers topics related to the major mechanical support structures of die casting machines; the machine base, rails, platen supports, wear pads, die carriers, tie bars and bushings.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

NADCA Video: The Role of Die Lubricants in Die Casting

Posted by Hill and Griffith Company on Oct 30, 2019 7:00:00 AM

NADCA Die Casting Video News & Information

The material presented in this video include highlights from NADCA’s online webinar - The Role of Die Lubricants in Die Casting. Die lubricants are a necessary part of high pressure die casting. The lubricant provides a thin layer to protect the die steel from molten metal. This presentation will discuss what die lubricants are and characteristics important to die casting, how to apply die lubricants in operation, problems caused by improper use of die lubricants, and alternatives to conventional die lubricants.


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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, NADCA Video Highlight

 


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