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

2. 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.

3. 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.

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
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.

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
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.

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
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 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

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 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

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