DIE CASTING COURSE

NADCA, the North American Die Casting Association 1999 http://www.diecasting.org

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

New Term

Metalcasting

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

Metal Casting History

An ancient industry:
Sand casting Investment casting Lost foam casting Permanent mold casting Centrifugal casting

All foundry processes

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

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

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
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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

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

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

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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

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Current Use of Castings

Cars Appliances Office equipment Sporting goods Machinery Toys Many other applications

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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

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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

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R&D of New Materials and Technologies

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

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Education and training

At Chicago headquarters At local chapters In-plant Through Learn@Home courses

Education for the Die Casting Industry

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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

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Marketing Statistics and Surveys

End Markets for Die Castings Financial Survey Die Cast Machine Study

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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

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Other Services

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

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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

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