Introduction to Die Casting,

Die Casting Machines and Dies

Introduction to Die Casting Series

Part 1 of 3
January 2015

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 Metal Casting
• Metalcasting U.S. Casting Facilities by Metal Type
700

– The industry of 600

pouring liquid metal 500

into a mold to 400

achieve a desired 300

shape. 200

100

– Many processes 0

are used for metal

casting
 Metal Casting History

• An ancient industry:
– Sand casting
– Investment casting
– Lost foam casting
– Permanent mold casting
– Centrifugal casting
• All foundry processes
 Sand, Investment, and Lost Foam Casting

• Use gravity to fill the mold

• Mold is destroyed to
remove casting
• Metal flow is slow
• Walls are much thicker
than in die casting
• Cycle time is longer than
die casting because of
inability of mold material
to remove heat
 Permanent Mold Casting

• Cousin to die casting

• Mold re-used, not destroyed
• Uses gravity to fill mold
• Metal flow is slow
• Mold is steel - has
comparatively good thermal conductivity
• Machines smaller
 Centrifugal Casting
• Frequently made by
jewelers
• The choice for low
volume castings with a
small amount of pressure
• Molds are placed around
the circumference of a
centrifuge
– As centrifuge spins, metal
poured in at center and
centrifugal force
distributes metal to the
molds
Die Casting vs Foundry Process
• Die casting is a variation of metalcasting
• Liquid metal injected into reusable steel mold, or
die, very quickly with high pressures
• Reusable steel tooling and injection of liquid
metal with high pressures differentiates die
casting from other metalcasting processes
 Die Casting History
• Begun during middle of
19th century
• In 1849, 1st machine for
casting printing type
• 20 years before began
casting other shapes
• Linotype machine direct
result of the casting of
printer’s type
• 1892 - parts for
phonographs, cash
registers
• 1900’S - babitt alloy
bearings produced
 Process Improvements

• To die steels
• To die construction
• In casting capability
• In production
capacity of the
process
Current Industry - 2014 Figures
• Approximately 375 die 2500000

casters in the USA with 2000000

sales of $6.8 billion. 1500000

• Die castings produced

from aluminum, copper, 1000000
Aluminum
lead, magnesium and 500000

zinc alloys as well as 0

various composite
materials 450000
• The top three alloys 400000
350000
were: 300000

– Aluminum 250000
200000 Zinc
– Zinc 150000
100000
– Magnesium 50000 Magnesium
0

2009
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008

2010
2011
2012
2013
 Current Use of Castings

• Cars
• Appliances
• Office equipment
• Sporting goods
• Machinery
• Toys
• Many other applications
 Types of Casting Operations

• “Captive” die caster

– Produces die castings
for their own use, for Captive
example, General
Motors
• “Custom” die caster
– Produce castings for
customers’ use
– Typically only Toolmaker
manufacture for other
companies, not
themselves
North American Die Casting Association (NADCA)

• North American trade

association is NADCA
• Mission is to be the
worldwide leader of
and resource for
stimulating continuous
improvement in the die
casting industry
• Provides services to its
members
 Die Casting Advantage
• Produces components
at high speed
• Uses a range of
durable metal alloys
• Captures the most
Metal: Magnesium
Alloy: AM60B
Weight: 18 lbs
intricate design details Description:
Crossover Vehicle
• So, it’s the choice for: Lift Gate Inner Panel

– High volume
production components
– Lower-volume
production as well
 Die Casting Applications
Other
Pumps & Comp- 19%
3%
Pipe & Fittings
15%
Municipal
3%

Spec Ind-3%
Car/Truck
Railroad-6% 32%

Farm Mach
3%

Valves-5%

Int Comb Eng Constr., Mining,

5% Oil Field-6%
 Optimum Configuration

• Fill completely with metal

• Solidify quickly without
defects
• Eject readily from the die
 Principle 1
• Wall thickness should be as consistent
as possible
 Principle 2
• Intersections of walls, ribs and gussets should
blend with transitions and generous radii
– Generous radii and transitions promote metal flow and
internal integrity
– Radii and fillets enhance structural integrity
– Fillets reduce heat concentration in both the die and
castings
 Principle 3
• Specify standard draft
– Draft is highly desirable on surfaces parallel to
the direction of die draw
– Recommended draft is determined by:
• The alloy
• The length of the dimension parallel to the die draw
• If the dimension is an inside or outside wall
 Principles 4 & 5
• Eliminate or minimize sharp corners
– Accommodate them at parting lines and at the junctions of
die components
– Break them with radii or chamfers
• Avoid undercuts
– May require machining operations or additional die
components, such as retractable core slides
 Principle 6

• Dimensions with critical tolerances should

relate to only one die member
 The Shot
• The result of injecting metal into the die,
i.e., making a shot (verb), is also called
a shot (noun)
• Shot elements:
– Runner
– Biscuit
– Overflows (not pictured)
– Casting
 Overflow
• A reservoir for the first
metal to flow through the Vent
cavity
• Vents inside provide a path Overflow
for air to get out of the die
– A strategically placed
overflow can be used to add
heat in a cold area of the die
• May help eject the casting
from the die
 Die Casting Processes
• Two Major Processes
– Hot chamber
– Cold chamber
• Get name from temperature of metal pump
relative to temperature of the metal
 Hot Chamber Process Uses

• For low melting point alloys

and alloys with a small
aluminum constituent
• These alloys include those
made from:
– Lead
– Tin
– Zinc
– ZA8 alloy
– a small amount of AZ91D
magnesium alloy
 Hot Chamber Components

• A Frame
• Shot Cylinder
• Plunger Coupler
• Plunger Rod
• Rings
• Gooseneck
• Nozzle
• Bushing
PLUNGER TIP & RINGS
Hot Chamber Machine Cycle
 Cold Chamber Process Uses

• Used for high melting point alloys and

alloys with a significant aluminum
constituent:
– Aluminum
– Magnesium
– Other Alloys Metal: Aluminum
Alloy: AA 367
• Copper Weight: 25 lbs
Size: Large(over 12X12)
• Titanium Description: Outboard
Marine Engine Drive
Shaft Housing
• Composite materials
 Cold Chamber Components
• C-frame
• Shot Cylinder
• Plunger Rod Coupler
• Cold Chamber
– Shot Sleeve
• Plunger Rod
– Shot Rod
• Plunger Tip
– Shot Tip
Cold Chamber Machine Cycle
 Hot Chamber Advantages
• Metal temperature control is better maintained
• Metal transfer not required
• Cooling of piston tip and sleeve not required
• Fewer oxidation losses
 Process Limitations/Variations
• Conventional process
limited by internal
porosity
– Due to trapped gases or
solidification shrinkage
• New technologies
developed to provide
denser castings
– Use vacuum, squeeze
casting, or semi-solid
and thixotropic
melting/casting
methods
 Vacuum Process

• Die cavity evacuated

using a vacuum
pump
• Several commercially
available systems
• Limitations to how
complete a vacuum
can be achieved; 26-
27 inches of mercury
seems adequate for
most applications
 Squeeze Casting
• Gate velocity
is much lower
• Gate
thickness is
much higher
• Metal
pressures at
the end of
cavity filling are
much higher
 Semi-Solid Casting
• Alloy cast is part liquid
and part solid
– Premise: defects form
during solidification;
solids therefore should
be free of defects
• Billet of material is
preheated to casting
temp. in a specially
constructed induction
heater
• Billet placed in cold
chamber, then injected
• Uses low gate velocities
and high metal
pressures to make very
dense castings
 Thixotropic Casting
• Takes advantage of the thixotropy of alloy
– When injected and forced through the gate, literally
sheared and agitated, it flows like a plastic material
• Injection system is a combination of the screw
used in plastic injection and the plunger used in
conventional die casting
 Die Casting Machines

• Structural
• Electrical
• Hydraulic
• Safety
 Structural Components
“C” Frame Cold Tie
Accumulator Bars
Chamber

Shot
Cylinder

Base
 Structural: Platens

• 3 Plates Carry Loads

• Rest on DCM Base
• Stationary: Stationary
– Holds Stationary/Cover MovingRear
Die Half
• Moving:
– Holds Moving/Ejector
Die Half
• Rear:
– Slides As Tie Bars
Stretch
 Stationary Platen
Stationary
MovingRear
Platens

Stationary platen showing the Tee-slots

and through hole for the cold chamber.
 Moving Platen
Stationary
MovingRear
 Rear Platen
Stationary
MovingRear
Structural: Tie bars
Structural: Toggle mechanism
 Electrical: Motor

• Electric motor(s) located at rear of DCM are

directly coupled to the hydraulic pump
• Electrical energy is converted into hydraulic
energy
• Pumps force oil into the
hydraulic lines under pressure
• Pose electric shock hazard
 Electrical: Solenoids

• Shift the valves that control the volume

and direction of hydraulic oil flow
Electrical: Limit Switches
 Hydraulic: Hydraulic pumps
• DCM typically has two hydraulic pumps
• One pump capable of providing oil at high
pressures but in low volumes
• A second pump capable of providing a high
volume of oil at low pressures
 Hydraulic: Filters
• Filter(s) are required to keep the hydraulic
fluid clean
– Located at the outlet of the pumps
• Require routine maintenance
 Hydraulic: Valves
• Used to control amount and direction of oil flow
– Solenoid-operated valves direct the flow to the head
or rod side of a cylinder or direct oil to shift a large
valve
• May be manually operated
• Series of valves mounted on a manifold may
control the DCM’s speed control
 Hydraulic: Heat Exchanger
• Operates similarly to a boiler
– Hot hydraulic oil and cooling water run through the
heat exchanger; the water cools the oil
• Leakage can be troublesome
– Hydraulic oil could be contaminated by water
– Cooling water could be contaminated by the hydraulic
oil
 Hydraulic: Cylinders
• Open and close
the DCM
• Inject the metal
into the die
• Operate the
ejection system
• Move slides on
the die
• Actuate a safety
ratchet and
open and close
a safety door at
the die parting
line
 Hydraulic: Injection Components

• Inject the metal

into the die
• Hot chamber
components include:
– Shot cylinder, plunger
coupling, plunger, rings,
gooseneck, bushing
and nozzle
Hydraulic: Injection Components
 Hydraulic: Accumulator

• A large steel tank

• Partially filled with
hydraulic oil
• Above oil is high-
pressure nitrogen gas
• Used when large
volume of oil required
 Hydraulic: Intensifier

• Hydraulic device that increases hydraulic fluid

pressure at end of injection stroke
• This high pressure dramatically increases the
metal pressure to:
– Squeeze additional metal
into the die cavity as the
metal shrinks
– Further compress
trapped gases
Safety
 Safety

Safety ratchet mounted on

top of rear platen

Safety ratchet mechanism

 Die Casting Dies
• Casting die has four
functions:
– Hold molten metal
in shape of desired
casting
– Provide means for
molten metal to get
into the space
where it is held in
desired shape
– Remove heat from
molten metal to
solidify it
– Provide for removal
of the solidified
metal
 Die Ownership

• Typically owned by
the OEM
• If operation is
Captive, they own
their own die.
 Types of Dies

•Single cavity die

•Produces one
casting at a time
•Multiple cavity die
•Produces more than
one casting at a time
•Family die
•Produces a number
of different parts
•Unit die
•OEM owns the unit
die and the custom die
caster owns the mold
base or unit die holder

Unit die
 Unit Die System

Advantages
Lower tooling costs
Shorter lead times
Potentially lower
piece part costs
Disadvantages
Reduced flexibility in
part design
Limited size
Possible problem
moving tooling from
one vendor to another
without additional
tooling costs
 Die Shapes the Die Casting
• Die = Many Steel Example of Ejector
Components Die Half
• Components Perform
Specific Functions
• Names Correspond to
Shot Feature

Die Casting Cavity

Runner

Biscuit (Cold Chamber)

Sprue (Hot Chamber)
 Die Components

Stationary Moving
67
Stationary Half Mold Base Components

• Clamp slots
• Guide pins
• Pryslots
• Mounting/clamp plate
 Moving Half Mold Base

• Align the two halves of the die

•Guide bushings
•Ejector Box components
•Parallels/rails
•Clamp plate
•Support pillars
•Ejector System components
•Ejector pins
•Return pins
•Ejector plate
•Ejector return plate
•Guided ejection
 Die Cavity: Cavity Block & Core Pins

• Cavity blocks
• Core pins Core pin
• Slides
• Carrier Casting

• Wedgelock
• Cam pin
• Cooling lines
• Heaters
 Die Cavity: Slides
Moving

Stationary

Slides
Die Cavity: Wedgelock, Cam Pins
Cover Die

Cam Pin

Core
Slide
Cavity Carrier

Wedgelock

Moving Die
Die Cavity: Cooling Lines

These cooling lines are drilled through the

cavities and mold base
 Die Casting Shot

• Several cavity features share same

terminology as the die cast shot
– Sprue
– Runner
– Gate
– Overflows
– Vents
 Summary

• Die casting began in the 19th century

• Castings today:
– Top alloys-aluminum, zinc, magnesium
– Used in a wide variety of items
– Produced by captive or custom die casters
• NADCA, is the trade association
representing the industry
– Provides many services to the industry
 Summary

• Many reasons to choose die casting over

a competing process
• Many product lines made from die
castings
• 6 principles must be followed to ensure
optimum design
 Summary

• Two major processes

– Components are similar
– Process used is based on alloy’s melting point
– Hot chamber process has several advantages
• Process variations are based on new
technologies
– Try to overcome conventional die casting’s
limitation of internal porosity
 Summary

• Structural system form the basis of the

machine, providing support
• Electrical system provide power to the
machine and control it
• Hydraulic system use a fluid, fire-resistant oil
to power the cylinders that make DCM move
• Safety components help prevent injuries and
accidents, when used appropriately and
coupled with safety-conscious actions
 Summary

• Casting die is the other

major component
– Has four functions
• Castings can be
manufactured by the
OEM or purchased
from a custom producer
• 4 casting die forms:
single cavity, multiple
cavity, family and unit
• A typical die contains 3
modules: stationary die
base, moving mold die
and ejector box
Questions
Name: Beau Glim
Phone: 847-808-3164
E-mail: glim@diecasting.org

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