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Chapter 1 ObjectivesChapter 1 Objectives

List the topics covered in this courseList the topics covered in this course Identify the two major differences between die Identify the two major differences between die

casting and other metal casting processescasting and other metal casting processes List the three elements that form the basis for List the three elements that form the basis for

most die casting materialsmost die casting materials List at least five services provided by the die List at least five services provided by the die

casting trade association, NADCAcasting trade association, NADCA

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New TermNew Term

MetalcastingMetalcasting• The industry of pouring liquid metal into a mold The industry of pouring liquid metal into a mold

to achieve a desired shape.to achieve a desired shape.

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Metal Casting HistoryMetal Casting History

An ancient industry:An ancient industry:• Sand castingSand casting• Investment castingInvestment casting• Lost foam castingLost foam casting• Permanent mold castingPermanent mold casting• Centrifugal castingCentrifugal casting

All foundry processesAll foundry processes

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Die Casting vs Foundry Die Casting vs Foundry ProcessProcess

Die casting is a variation of metalcastingDie casting is a variation of metalcasting Liquid metal injected into reusable steel Liquid metal injected into reusable steel

mold, or die, very quickly with high mold, or die, very quickly with high pressures pressures

Reusable steel tooling and injection of liquid Reusable steel tooling and injection of liquid metal with high pressures differentiates die metal with high pressures differentiates die casting from other metalcasting processescasting from other metalcasting processes

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Sand, Investment, and Sand, Investment, and Lost Foam CastingLost Foam Casting

Use gravity to fill the moldUse gravity to fill the mold Mold is destroyed to remove castingMold is destroyed to remove casting Metal flow is slowMetal flow is slow Walls are much thicker than in die castingWalls are much thicker than in die casting Cycle time is longer than die casting because Cycle time is longer than die casting because

of inability of mold material to remove heatof inability of mold material to remove heat

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Permanent Mold CastingPermanent Mold Casting

Cousin to die castingCousin to die casting Mold removed, not destroyedMold removed, not destroyed Uses gravity to fill moldUses gravity to fill mold Metal flow is slowMetal flow is slow Mold is steel - has Mold is steel - has

comparatively good thermal conductivitycomparatively good thermal conductivity Machines smallerMachines smaller

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Centifugal CastingCentifugal Casting

Frequently made by jewelersFrequently made by jewelers The choice for low volume castings with a The choice for low volume castings with a

small amount of pressuresmall amount of pressure Molds are placed around the circumference Molds are placed around the circumference

of a centrifuge of a centrifuge • As centrifuge spins, metal poured in at center As centrifuge spins, metal poured in at center

and centrifugal force distributes metal to the and centrifugal force distributes metal to the moldsmolds

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Die Casting HistoryDie Casting History

Begun during middle of 19th century Begun during middle of 19th century In 1849, 1st machine for casting printing typeIn 1849, 1st machine for casting printing type 20 years before began casting other shapes 20 years before began casting other shapes Linotype machine direct result of the casting Linotype machine direct result of the casting

of printer’s typeof printer’s type 1892 - parts for phonographs, cash registers1892 - parts for phonographs, cash registers 1900’S - babitt alloy bearings produced1900’S - babitt alloy bearings produced

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History of Casting AlloysHistory of Casting Alloys

Various compositions of tin and lead were the Various compositions of tin and lead were the first die casting alloys first die casting alloys

Development of zinc alloys just prior to World Development of zinc alloys just prior to World War I caused decline of tin and leadWar I caused decline of tin and lead

Magnesium and copper used next Magnesium and copper used next 1930s-many of today’s alloys developed 1930s-many of today’s alloys developed Still making refinements resulting in new Still making refinements resulting in new

alloys with increased strength and stabilityalloys with increased strength and stability

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Process ImprovementsProcess Improvements

To die steelsTo die steels To die constructionTo die construction In casting capabilityIn casting capability In production capacity of the processIn production capacity of the process

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Current Industry - 1995 Current Industry - 1995 FiguresFigures

Approximately 450 die casters in North America Approximately 450 die casters in North America with sales of $8 billion with sales of $8 billion

Die castings produced from aluminum, copper, Die castings produced from aluminum, copper, lead, magnesium and zinc alloys as well as various lead, magnesium and zinc alloys as well as various composite materials composite materials

The top three alloys were:The top three alloys were:• AluminumAluminum• ZincZinc• MagnesiumMagnesium

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Current Use of CastingsCurrent Use of Castings

CarsCars AppliancesAppliances Office equipmentOffice equipment Sporting goodsSporting goods MachineryMachinery ToysToys Many other applicationsMany other applications

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Types of Casting Types of Casting OperationsOperations

““Captive” die casterCaptive” die caster• Produces die castings for their own use, for Produces die castings for their own use, for

example, General Motorsexample, General Motors ““Custom” die casterCustom” die caster

• Produce castings for customers’ useProduce castings for customers’ use• Typically only manufacture for other companies, Typically only manufacture for other companies,

not themselvesnot themselves

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North American DieNorth American DieCasting Association Casting Association (NADCA)(NADCA)

North American trade association is NADCA North American trade association is NADCA Mission is to be the worldwide leader of and Mission is to be the worldwide leader of and

resource for stimulating continuous resource for stimulating continuous improvement in the die casting industryimprovement in the die casting industry

Provides services to its membersProvides services to its members

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R&D of New Materials R&D of New Materials and Technologiesand Technologies

Die casting alloy performanceDie casting alloy performance Die lifeDie life Process capabilityProcess capability Process simulationProcess simulation Energy conservationEnergy conservation Environmental management/pollution preventionEnvironmental management/pollution prevention Rapid toolingRapid tooling

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Education and trainingEducation and training

At Chicago headquartersAt Chicago headquarters At local chaptersAt local chapters In-plantIn-plant Through Learn@Home coursesThrough Learn@Home courses

“Education for the Die Casting Industry”

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Government Relations, Government Relations, Safety, and AwardsSafety, and Awards

Source for federal govt. relations activity Source for federal govt. relations activity Speak with single voice in Washington, D.C. Speak with single voice in Washington, D.C.

• $5.8 million in DOE research dollars in 1998$5.8 million in DOE research dollars in 1998 Recognizes outstanding safety recordsRecognizes outstanding safety records Annual Awards to distinguished members Annual Awards to distinguished members Annual scholarships awardedAnnual scholarships awarded

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Marketing Statistics and Marketing Statistics and SurveysSurveys

End Markets for Die CastingsEnd Markets for Die Castings Financial SurveyFinancial Survey Die Cast Machine StudyDie Cast Machine Study

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Meeting. Conferences, Meeting. Conferences, and Expositionand Exposition

International Congress and Exposition held International Congress and Exposition held every two yearsevery two years

Other conferences and meetings, including:Other conferences and meetings, including:• Plant Management ConferencePlant Management Conference• Government Affairs BriefingGovernment Affairs Briefing• Die Materials ConferenceDie Materials Conference• Computer ModelingComputer Modeling• Technology WorkshopsTechnology Workshops

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Other ServicesOther Services

Die Casting Die Casting Engineer MagazineEngineer Magazine

Publications, Publications, software and videosoftware and video

Diecasting Development Diecasting Development CouncilCouncil

NADCA website at NADCA website at www.diecasting.orgwww.diecasting.org

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SummarySummary

Die casting began in the 19th century Die casting began in the 19th century Castings today:Castings today:

• Top alloys-aluminum, zinc, magnesiumTop alloys-aluminum, zinc, magnesium• Used in a wide variety of itemsUsed in a wide variety of items• Produced by captive or custom die castersProduced by captive or custom die casters

NADCA, is the trade association representing NADCA, is the trade association representing the industry the industry • Provides many services to the industryProvides many services to the industry