Chapter 1 Objectives

1
Chapter 1 Objectives

• List the topics covered in this course
• Identify the two major differences between die
  casting and other metal casting processes
• List the three elements that form the basis for
  most die casting materials
• List at least five services provided by the die
  casting trade association, NADCA

2
New Term

• Metalcasting
• The industry of pouring liquid metal into a mold
  to achieve a desired shape.

3
Metal Casting History

• An ancient industry
• Sand casting
• Investment casting
• Lost foam casting
• Permanent mold casting
• Centrifugal casting
• All foundry processes

4
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

5
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

6
Permanent Mold Casting

• Cousin to die casting
• Mold removed, not destroyed
• Uses gravity to fill mold
• Metal flow is slow
• Mold is steel - has comparatively good thermal
  conductivity
• Machines smaller

7
Centifugal 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

8
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
  printers type
• 1892 - parts for phonographs, cash registers
• 1900S - babitt alloy bearings produced

9
History of Casting Alloys

• Various compositions of tin and lead were the
  first die casting alloys
• Development of zinc alloys just prior to World
  War I caused decline of tin and lead
• Magnesium and copper used next
• 1930s-many of todays alloys developed
• Still making refinements resulting in new alloys
  with increased strength and stability

10
Process Improvements

• To die steels
• To die construction
• In casting capability
• In production capacity of the process

11
Current Industry - 1995 Figures

• Approximately 450 die casters in North America
  with sales of 8 billion
• Die castings produced from aluminum, copper,
  lead, magnesium and zinc alloys as well as
  various composite materials
• The top three alloys were
• Aluminum
• Zinc
• Magnesium

12
Current Use of Castings

• Cars
• Appliances
• Office equipment
• Sporting goods
• Machinery
• Toys
• Many other applications

13
Types of Casting Operations

• Captive die caster
• Produces die castings for their own use, for
  example, General Motors
• Custom die caster
• Produce castings for customers use
• Typically only manufacture for other companies,
  not themselves

14
North American DieCasting 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

15
RD of New Materials and Technologies

• Die casting alloy performance
• Die life
• Process capability
• Process simulation
• Energy conservation
• Environmental management/pollution prevention
• Rapid tooling

16
Education and training

• At Chicago headquarters
• At local chapters
• In-plant
• Through Learn_at_Home courses

Education for the Die Casting Industry
17
Government Relations, Safety, and Awards

• Source for federal govt. relations activity
• Speak with single voice in Washington, D.C.
• 5.8 million in DOE research dollars in 1998
• Recognizes outstanding safety records
• Annual Awards to distinguished members
• Annual scholarships awarded

18
Marketing Statistics and Surveys

• End Markets for Die Castings
• Financial Survey
• Die Cast Machine Study

19
Meeting. Conferences, and Exposition

• International Congress and Exposition held every
  two years
• Other conferences and meetings, including
• Plant Management Conference
• Government Affairs Briefing
• Die Materials Conference
• Computer Modeling
• Technology Workshops

20
Other Services

• Die Casting Engineer Magazine
• Publications, software and video
• Diecasting Development Council
• NADCA website at www.diecasting.org

21
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