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 printer’s type • 1892 - parts for phonographs, cash registers • 1900’S - 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 today’s 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. 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

16. Education and training • At Chicago headquarters • At local chapters • In-plant • Through Learn@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