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Die Casting News

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

Video News Update: Advanced Approach to Die Casting Process Control

Posted by Hill and Griffith Company on Oct 23, 2019 7:00:00 AM

NADCA Video News & Information

The material presented in this video are some highlights from NADCA’s online webinar - Advanced Approach to Die Casting Process Control. In this we define what variables we have control of and what impact this has on the many variables that we can’t directly control. This then covers the die casting measurements that should be taken and the great care in choosing the right variables to measure. This data is then used in two ways, 

  • Historical - what was measured in the past and how can the company gain the best information.
  • Planned Trials - what is available to let the company carry out a multi variable experiment and gain the best advantage for future production.


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

Video-High Integrity Die Casting: The market, Applications and Commercial Aspects

Posted by Hill and Griffith Company on Aug 8, 2019 3:19:45 PM

NADCA Video News & Information

The material presented in this video include highlights from NADCA’s online webinar - High Integrity Die Casting: The Market, Applications and Commercial Aspects of High Integrity Die Casting. In this webinar the rapidly growing market for high integrity die castings is presented and applications in the various market segments are discussed. The main growth sector is automotive, where there are increased car body applications like shock towers. This is not the only market segment where structural high integrity die castings are increasingly used. We can find structural high integrity die castings more in motorcycles, recreational vehicles and also boats.

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

Article Excerpt: Improving Surface Finishing of Die Castings

Posted by Hill and Griffith Company on Jul 31, 2019 3:07:59 PM

Upfront Collaboration Between Casting Supplier and End User Can Improve Post-Casting Processing, from Finishing to Painting

by Joe Miller, Chicago White Metal Casting Inc., Bensenville, Illinois

A plastic bumper joining this two-part case conceals all parting lines, thus avoiding any edge polishing.

In the die casting process, metal molds—or dies—are preheated and coated with a die release agent prior to the injection of molten metal that is forced into the die under extreme pressure (usually from 10,000 to 15,000 psi). But once they are ejected from the die, most parts have a journey ahead of them before arriving at the shipping department.


The large majority of die castings require specific coatings and finishes, polishing and/or painting. These processes are necessary to meet cosmetic/decorative appearance requirements, enhance wear resistance and/or provide a protective barrier against corrosion. Read the entire article here, on the MetalCastingDesign.com site.

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Tags: Die Casting, Metal Casting, Aluminum Die Casting Process, Die Casting Release Agent, Die Casting Defects, Metal Casting Design & Purchasing

 


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