North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Examples of Cavitation Effect in Die Casting G. L. Lockwitz Harley-Davidson Motor Co.

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Universal Die Casting in 1980’s Zinc tool Wind Split molding – car hood Cast holding studs Specs H ft/sec Rc 400 degrees surface of steel Pour about 850 degrees

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Universal Failure Sampling ran 50 shots Took out for die prep Large pit in cover half about.020 dia and deep

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Cavitation 50 shots Gate Pit in this area Wind split molding Side view of casting section with cast stud

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Stopped Cavitation Effect Welded pit Eyebrow added to gate in line with flow Diverted metal which changed pressure drop Ran 100,000+ with no further problem. Effectively the eyebrow did not allow a local pressure drop in this area to fall below the vapor pressure of the zinc Cavitation inception did not occur

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA The fix – change flow pattern Gate Wind split molding Diverter in gate Side view of casting section with cast stud

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA H-D Rocker Cover High Cosmetic requirement Early die replacement (25K shots) Cavitation effect on fillets and radii Excellent die tracking by caster Photos taken every 5,000 shots

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA Harley Rocker Cover #89 – 35,000 Shots Casting Photos Gated on this side

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA #98 Rocker – 15,000 Shots

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA #103 Rocker – 65,000 Shots

North American Die Casting Association – 114 th Metalcasting Congress CastExpo’10, March 20-23, 2010 Orlando, Florida USA #104 Rocker – 61,600 Shots