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 Review course objectives. Tell participants that all testing will be based on the course and chapter level objectives.

New Term Metalcasting The industry of pouring liquid metal into a mold to achieve a desired shape. Discuss sand, investment, and lost foam casting. Use gravity to fill the mold. The mold is destroyed to remove the casting. Mold making is as important part as is making the casting. Metal flow is slow. Walls are much thicker than in die casting. Cycle time longer because of inability of mold material to remove heat. Discuss permanent mold casting. A cousin to die casting. The mold is reused, not destroyed. The process uses gravity to fill the casting. Mold is steel with comparatively good thermal conductivity, hence the release agents used in this process are also insulators. This keeps the casting from freezing periodically and prevents filling. Machines for this process are smaller than machines used to die cast for similar sized castings. Discuss centrifugal casting. Frequently made by jewelers. The choice for low volume castings with a small amount of pressure. The molds are placed around the circumference of a centrifuge. As the centrifuge spins, metal is poured in at the center and centrifugal force distributes the metal to the molds.

Metal Casting History An ancient industry: All foundry processes Sand casting Investment casting Lost foam casting Permanent mold casting Centrifugal casting All foundry processes Discuss sand, investment, and lost foam casting. Use gravity to fill the mold. The mold is destroyed to remove the casting. Mold making is as important part as is making the casting. Metal flow is slow. Walls are much thicker than in die casting. Cycle time longer because of inability of mold material to remove heat. Discuss permanent mold casting. A cousin to die casting. The mold is reused, not destroyed. The process uses gravity to fill the casting. Mold is steel with comparatively good thermal conductivity, hence the release agents used in this process are also insulators. This keeps the casting from freezing periodically and prevents filling. Machines for this process are smaller than machines used to die cast for similar sized castings. Discuss centrifugal casting. Frequently made by jewelers. The choice for low volume castings with a small amount of pressure. The molds are placed around the circumference of a centrifuge. As the centrifuge spins, metal is poured in at the center and centrifugal force distributes the 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 Explain process. Die casting is a process involving the injection of molten metal at high pressures (as opposed to casting by gravity pressure). Discuss history. Begun sometime during the middle of the 19th century. In 1849 Sturges patented the first manually operated machine for casting printing type. Process was eventually extended to casting other shapes. The casting of printer’s type led to patents that eventually resulted in development of the linotype machine by Ottmar Mergenthaller. Discuss commercial applications. In 1892, parts were produced for phonographs and cash registers. H.H. Franklin Company began die casting babitt alloy bearings for automobile connecting rods shortly after the turn of the century. Discuss casting alloys. Tin and lead were the first die casting alloys, but declined with the development of zinc alloys just prior to World War I. Magnesium and copper followed shortly thereafter. Modern science and technology, metallurgical controls and research make further refinements possible resulting in new alloys with increased strength and stability.

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 Explain process. Die casting is a process involving the injection of molten metal at high pressures (as opposed to casting by gravity pressure). Discuss history. Begun sometime during the middle of the 19th century. In 1849 Sturges patented the first manually operated machine for casting printing type. Process was eventually extended to casting other shapes. The casting of printer’s type led to patents that eventually resulted in development of the linotype machine by Ottmar Mergenthaller. Discuss commercial applications. In 1892, parts were produced for phonographs and cash registers. H.H. Franklin Company began die casting babitt alloy bearings for automobile connecting rods shortly after the turn of the century. Discuss casting alloys. Tin and lead were the first die casting alloys, but declined with the development of zinc alloys just prior to World War I. Magnesium and copper followed shortly thereafter. Modern science and technology, metallurgical controls and research make further refinements possible resulting in new alloys with increased strength and stability.

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

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

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

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

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

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 example, General Motors “Custom” die caster Produce castings for customers’ use Typically only 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

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

Education and training At Chicago headquarters At local chapters In-plant Through Learn@Home courses “Education for the Die Casting Industry”

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

Marketing Statistics and Surveys End Markets for Die Castings Financial Survey Die Cast Machine Study

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

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

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