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Die Casting News

Effective Die Coating for Maximum Value

Posted by Hill and Griffith Company on Nov 25, 2020 8:00:00 AM

Excerpt from the Jan. 2013 Foundry & Management Technology article by John Hall.

Starting a new die Die coating application Die heating, coating

Die coating in gravity diecasting is one of the operational parameters of the casting process that is often overlooked or misunderstood. Die coatings are necessary for three basic reasons.

Coatings provide a protective barrier between the die and the casting to prevent die erosion and wear. Coatings provide some degree of control over the solidification rate and direction. Coatings provide a barrier between the die and casting so that the casting will release from the die.

With proper use, a die coating can be used to control the thermal gradients such that directional solidification can be achieved.  This allows a pathway for feed metal to flow into the solidifying structure and compensate for normal metal shrinkage during solidification.  This is particularly important in castings with thin sections that expand to thicker sections:  The thin areas must remain open to ensure that shrinkage will not occur in the adjacent thick section.

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Squeeze Casting

Modeling the Mechanical Performance of Die Casting Dies

Posted by Hill and Griffith Company on Nov 18, 2020 1:53:58 PM

Excerpt from the report by Ohio State Industrial, Welding and Systems Engineering professor R. Allen Miller.

2.1 Characterization of loads on die and machine

The die and the machine together function as a system. Analysis of both is important in understanding the distortions of the die. The die and the machine are subject to thermal and mechanical loads during the course of a casting cycle. These forces cause the die and machine behavior to change due to deflection and distortion of the components in their assembly. For studying the loads on the die casting die, the process has to be studied over an entire casting cycle. The forces can broadly be categorized as mechanical loads and thermal loads.

The different stages of a casting cycle are listed below:

1. The die locks up and a clamping force is applied.
2. Hot molten metal is injected at high temperature. The loads involved are due to momentum of incoming metal, heat released during the filling process, and the sudden pressure spike as the cavity becomes completely full.
3. The molten metal is held inside the die and an intensification pressure is applied during solidification.
4. The part is held in the die for a short time to remove additional heat.
5. The die is opened and the part ejected.
6. The die remains open for lubricant and cooling spray and the cycle repeats.

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Squeeze Casting

Squeeze Casting: Part One

Posted by Hill and Griffith Company on Oct 14, 2020 1:36:07 PM

Excerpt from the June 2007 TotalMateria.com article.

Squeeze casting as liquid-metal forging is a process by which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press.
The applied pressure and instant contact of the molten metal with the die surface produce a rapid heat transfer condition that yields a pore-free fine-grain casting with mechanical properties approaching those of a wrought product. The squeeze casting process is easily automated to produce near-net to net shape high-quality components.

The process was introduced in the United States in 1960 and has since gained widespread acceptance within the nonferrous casting industry. Aluminum, magnesium, and copper alloy components are readily manufactured using this process. Several ferrous components with relatively simple geometry, for example, nickel hard-crusher wheel inserts-have also been manufactured by the squeeze casting process.

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Tags: Die Casting, Squeeze Casting Release Agents, Die Casting Lubricants, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Squeeze Casting, TotalMateria.com


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