EC-102 Introduction To Die Casting  - REGISTER

A one-day course devoted to familiarizing students, designers, engineers and interested buyers with the die casting process. NADCA has prepared this course to review the basics of die casting. This course will provide specifications for various alloys, briefly explaining the types of machines used to cast these alloys and information that compares the die casting process to other processes.

Workshop Summary

Die casting is a most versatile process for producing complex-shaped engineered metal parts, with a high degree of accuracy and repeatability. It permits wide latitude and flexibility in design. It is suitable for casting textured surfaces, and permits the application of a wide variety of attractive and serviceable finishes.

Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry. Die castings are important components in thousands of consumer, commercial and industrial products such as automobiles; household appliances; recreation, hobby and leisure products; farm and garden equipment; electrical equipment and ordnance; general hardware; power tools; computers and other business equipment; instruments; toys; novelties; and a great many others too numerous to mention. In fact, die castings have greater utility and are used in more applications than components produced by almost any other metal forming process.

Materials
Introduction to Die Casting
Dictionary of Die Casting Terms

Instructors
Henry Bakemeyer
Scott Kirkman
Jerry Wilkey

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EC-201 Magnesium Die Casting - REGISTER

A one-day course providing students with the basics of the various aspects of magnesium die casting including safety and environmental considerations of magnesium.

Workshop Summary

This course covers magnesium die casting alloys, melting and handling magnesium, magnesium die casting equipment and dies, safety and environmental considerations, and finishing/secondary operations. The information in this course is targeted for production and non-production employees requiring an overview of magnesium die casting.

Materials
Magnesium Die Casting Handbook

Instructors
Henry Bakemeyer
Colin Chapman
Mike Ward

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EC-202 Zinc Die Casting - REGISTER

A one-day course providing students with the basics of the various aspects of zinc and mini-zinc die casting. Information specific to zinc and mini-zinc casting is presented and, where applicable, the differences between aluminum and magnesium die casting are identified. 

Workshop Summary

This course covers zinc alloys, melting and handling zinc, zinc die casting equipment and dies, the zinc die casting process, defects and secondary operations. The information in this course is targeted for production and non-production employees requiring an overview of zinc and/or mini-zinc die casting.

Materials
The Zinc Die Casting Process

Instructors
Henry Bakemeyer
Ed Herman

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EC-205 Quick Die Change (SMED) - REGISTER

A one-day course essential to learning how to do die casting die changeover/setups in record time. The goal is SMED (single minute exchange of dies), a die changeover in less than 10 minutes.  This course utilizes lean manufacturing methodologies.

Workshop Summary

This course is a guide to understanding and implementing SMED.  Installation steps, design standardization and training strategies are discussed.  The SMED methodology is simple and applies to all die or tooling exchanges.  It works in all languages and companies around the world can use this to achieve better product quality and higher productivity.

Materials
Guide to Quick Die Changes

Instructors
Henry Bakemeyer
 

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EC-211 Dimensional Repeatability - REGISTER

A one-day program devoted to identifying and understanding the significant variables in the die casting process that cause dimensional variation between castings. This course demonstrates the use of mathematical cause and effect relationships to predict specific results.

Workshop Summary

This course, targeted to the product and tool designers; process engineers and technicians; quality control managers, technicians and inspectors; manufacturing supervisors and operators; maintenance and tool room managers; and mechanics and toolmakers, discusses the dimensional variation in general. A brief review of basic statistical concepts is included, including histograms and average and range charts. Also discussed are the four major types of dimensional variation. The process variables that contribute to the major types of dimensional variation are explored and evaluated. Finally, variation due to measurement is discussed. The two components of measurement variation are R&R, repeatability (equipment variation) and reproducibility (operator variation).

Materials
Dimensional Repeatability
Handouts

Instructors
Henry Bakemeyer
Rex Fish
Bruce McFadzean
Don Tremblay

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EC-302/3 Metal Melting and Handling - REGISTER

A one-day workshop dedicated to understanding and controlling metal quality and melt temperature, the most important variables in the die casting process. They are essential to control to meet quality and integrity standards.

Workshop Summary

This course covers basic principles in the melting, handling and melt treatment of aluminum die cast alloys to deliver high quality metal to the die casting machine. The course is intended for melt room personnel, managers, engineers, metallurgists, technicians and quality assurance personnel. However, machine operators and all other die cast shop personnel will benefit from understanding how molten metal handling and quality affects the entire die casting process.

Specific items that are covered include safety in melting and handling; charge materials, practices and features of specific melting furnaces; pouring practices; origins of melt quality problems, including hydrogen absorption, inclusions, dross formation, corundum formation and sludge; and principles and examples of specific melt treatments normally utilized to alleviate these problems, including fluxing, flux injection, degassing and filtration.

Materials
High Integrity Aluminum Die Casting
Handouts

Instructors
Henry Bakemeyer
David Neff

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EC-305 Metallurgy Of Aluminum Die Casting Alloys  - REGISTER

A one-day workshop dedicated to understanding the properties of aluminum alloys, the significance of constituents and impurities, and the importance of metallurgical structures. The behavior of alloys and solid solutions during and after solidification is examined assuring a practical focus on real-life, everyday metallurgical problems.

Workshop Summary

This course covers the metallurgical principles involved in aluminum die casting alloys. The level of the course material is aimed primarily at technical and management personnel. Specific items that are covered include alloy specifications; specific roles of alloying silicon, copper, magnesium, iron and minor elements; understanding phase diagrams and microstructures; mechanical properties, heat treating and machining. Extensive presentation and discussion is focused on the role of impurities, analytical techniques for assessing melt cleanliness and subsequent melt treatment. The latter includes the technical/scientific principles of degassing, fluxing/flux injection, modification and filtration. The final segment of the course briefly surveys other casting processes and emerging technology.

Materials
High Integrity Aluminum Die Casting
Handouts

Instructors
Henry Bakemeyer
David Neff
John Wronowicz

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EC-406 Machine Maintenance: Hydraulics  - REGISTER

A three-day program devoted to improving the performance of the hydraulic systems in die casting equipment through understanding and applying the principles to effective maintenance programs.

Workshop Summary

Perhaps no form of power is more universally used than hydraulic power. In die casting equipment, hydraulic systems are an integral part of the process to produce high quality parts within cost parameters. However, it is clear that with increased technology and automation, hydraulic circuits have become much more complex in the way they interact with electro-mechanical-PLC processes. Troubleshooting and maintaining hydraulic components have become all the more important to the successful daily operation of die casting equipment. This workshop is dedicated to understanding and implementing hydraulic principles in troubleshooting and maintenance of hydraulic circuits.

The workshop reviews the definitions and principles that govern how hydraulic processes work, including Pascal’s law, force multiplication, laminar flow-turbulent flow, and basic formulas. Other areas covered include energy inputs and outputs; pressure, directional and flow control valves; auxiliary circuits; hydraulic circuits; and maintenance and troubleshooting. A major feature of the workshop is the opportunity for participants to troubleshoot and problem-solve.

Materials
Vickers Industrial Hydraulics Manual
Vickers supplements

Instructors
Wayne Alofs
Paul Cnossen
Ed Wrench

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EC-407 Mechanical Maintenance: Mechanics  - REGISTER

A two-day program dedicated to developing a practical level of understanding of how the die casting machine works, how to evaluate the condition of the machine, how to identify defects and how to make repairs.

Workshop Summary

The die casting machine is a marvel of engineering, design and complexity and can provide years of dependable service, provided it is effectively maintained. When a machine is not in good condition, the casting process is affected. The life of the machine is reduced along with die life, which has a direct effect on productivity and quality of products. Meeting customer needs is directly correlated to machine maintenance.

This program addresses the mechanics of the die casting machine, from the foundation it sits on, to its maze of linkages, to the die itself. The focus is on the practical requirements of machine repair and preventative maintenance. The course emphasizes the mechanics and assembly of the die casting machine.

Materials
Mechanical Maintenance and Evaluation of Die Cast Machines

Instructors
Wayne Alofs
Paul Cnossen
Ed Wrench

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EC-408/9 Machine Maintenance: Electricity - REGISTER

A two-day program devoted to understanding and implementing a practical approach to circuit design, maintenance and troubleshooting of electrical control systems used in die casting.

Workshop Summary

This course is designed for those responsible for designing, maintenance and repair of die casting equipment and secondary operations machinery and anyone who comes in contact with control systems during their daily routine. A major emphasis is put on developing troubleshooting skills for both relay logic control systems and programmable controllers. With today’s advanced technology and the use of programmable controllers expanding at an ever-increasing rate, those companies and individuals who are to survive the competition and technological challenges of the future are sure to find a powerful tool in the use and application of PLCs to machine systems and processes.

This course will focus on basic electrical principles; all major components used in the die casting industry; understanding, developing and using electrical schematics for troubleshooting; introduction to programmable logic controllers (PLCs); understanding, developing and programming PLCs; and troubleshooting and maintenance of control systems.

Materials
Electrical Controls for Machines
Handouts

Instructor
Paul Cnossen
Ed Wrench

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EC-410 Process Control  - REGISTER

A one to two-day program devoted to understanding, practicing and implementing control over the combination of mechanical, hydraulic, electrical, thermal, metallurgical and feedback processes that function simultaneously in the die casting process.

Workshop Summary

The primary purpose of this course is to show the processing engi­neer and operating technician what type of control method is applicable to each of the die casting machine/die/process systems, how to measure the performance of each critical variable, compare actual performance to the desired and to adjust the actual performance to meet the desired. The student will find this 2003 revision of the course more definitive and focused than the previous as the machine systems portion of the previous has been split off as a separate two-day offering.

Materials
Die Casting Process Control

Instructors
Wayne Alofs
Paul Cnossen
Ed Herman
Scott Kirkman
Don Tremblay
Bill Walkington
Mike Ward
Ed Wrench

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EC-411 Die Casting Lubricants and Coolants - REGISTER

A one-day course that provides an in-depth examination of temperature control issues within the die casting process.

Workshop Summary

A discussion of metal temperature control will explore not only furnace and distribution system issues but also will investigate the effects of metal temperature control on both casting quality and process. Die temperature control will look at measurement techniques, die sprays, cooling lines and the effect of cycle timing on die temperatures and casting quality. An in-depth discussion of both die and plunger lubricants will look at their chemistry, function, application and effects on casting production and quality as well as EPA and OSHA considerations in the workplace.

Materials
Handouts

Instructors
Henry Bakemeyer
Tom Camel
Scott Kirkman
Mark Osborne

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EC-413 Die Cast Problem Solving  - REGISTER

A two-day course designed to solve difficult die cast problems that can’t be solved through conventional process engineering methods.

Workshop Summary

This course is specifically designed for die casting by focusing on the interactive nature of the die casting process. The course teaches logical and statistical methods that do not require a strong mathematics background. Prerequisites for this course are a basic understanding of algebra and statistical concepts such as standard deviation and variation. The course includes concepts from the following sources: Dorian Shainin-Statistical Engineering; Ford Motor Co.-Team Oriented Problem Solving; Box, Hunter and Hunter-Statistics for Experimenters; General Motors Co.-Problem Solving Basics; and Taguchi-Design of Experiments. The course will enable improved, data-driven process decision making; promote statistical thinking in regard to process variation; develop an objective defect ranking system for a subjective defect; correlate the process to the defect without preconception.

Materials
Die Cast Problem Solving

Instructor
Ed Herman
Scott Kirkman

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EC-415 Die Cooling Systems Engineering  - REGISTER

A two-day course designed to teach participants how to calculate the required amount of heat energy to process through a die casting die using the principles of heat transfer.

Workshop Summary

Controlling the temperature of a die casting die through the location of cooling lines is critical to performance and die life. A properly designed system of water and/or oil lines will process heat energy so the die can be operated productively with the highest part quality possible. An improperly designed cooling system will have detrimental effects on production, quality and die life. During the course, conduction and convection will be used treating the die as a steady-state, one-dimensional heat flow system. Factors for normal losses and external cooling will be discussed. Engineering-based calculations will be used to determine depth and length of cooling channels required to process the amount of heat energy input from the casting process. A procedure for die cooling system design will be established and a summary of general rules and guidelines will be included. Special cooling methods will be covered including bubblers and fountains; thermal pins; and treatment of concave and convex surfaces.

Materials
Die Cooling Systems Engineering

Instructors
Scott Kirkman

Craig Nelson
Mark Osborne
Mike Ward

EC-420 Machine Systems - REGISTER

A one to two-day course created from portions of the Process Control course prior to the 2003 version and dedicated to providing a basic understanding of the die casting machine and how it works to Operating Technicians, Die Casting Technicians, Die Casting Engineers, Tooling Engineers and Maintenance personnel. 

It is recommended that anyone taking this course be well grounded in basic shop math and have the equivalent understanding of the die casting process as presented in the NADCA courses on Introduction to Die Casting, Die Casting Machine Safety and Metal Melting and Handling.

Workshop Summary:

The die casting machine consists of three basic mechanical systems (plus the machine controls) to accomplish these tasks.  These are: 1) the clamp system; 2) the ejection system, and; 3) the metal injection (i.e. “Shot”) system.  These systems are the focus of and described in this course along with instructions for their proper adjustments.  Also included are descriptions of how the dies must be properly sized to the machine and how to measure the machine’s performance capabilities.

The course has been created by splitting-off and expanding upon the machine system information that was presented in a previous version of Process Control.  It was recognized that the two subjects are tightly related, but the combined subject material is too much for the NADCA course format to present as a single subject, and that the machine systems subject matter is background information for several other branches of study.  For example, this two-day Machine Systems course should be considered as prerequisite for further study in Process Control and all aspects of Machine Maintenance (i.e. mechanical, hydraulic and electrical).  The material in this course is also essential information when one specifies a die casting machine for purchase, evaluates various machines for possible purchase and/or installs a new machine.  This course and accompanying text provides one of the major cornerstones of the NADCA Education Program.

Materials
Die Casting Machine Systems

Instructors

Henry Bakemeyer
Paul Cnossen
Ed Herman
Scott Kirkman
 

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EC-430 Process Monitoring - REGISTER

A one day course that covers shot end, thermal, cycle time, and other important die cast process variable monitoring and control.  The course surveys the current monitoring and control products in the die casting industry to show monitoring approaches currently in place.  The course also covers areas of improvement needed from the process monitoring suppliers to best reflect process data needed to verify good die cast process design.   

This course is designed for the die casting employee, engineer, or manager who has a basic understanding and some experience using process monitoring and control systems and would like to gain a more thorough understanding.  The course will help the die casting employee understand the relationship between the data received from the process monitoring system and product quality.  It will also provide guidelines on the uses of process control to maintain product quality.  Although, die casting concepts are covered in detail, no significant mathematical skill or process experience is required.

Materials
Guide to Process Monitoring & Control

Instructors
Ed Herman
Scott Kirkman

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EC-501 Die Material Metallurgy And Extending Die Life  - REGISTER

A two-day program devoted to understanding the basic metallurgy of die materials, including problems, principles, alloying effects, heat treating, die finishing and surface treatments. A special feature will be the die welding portion of the workshop.

Workshop Summary

Understanding die material metallurgy is critical to extending die life and to effective overall cost reduction. The class will begin with an introduction and will cover improving die life and reducing cost through metallurgy. There will be a review of typical problems, cost and problems analysis and avoidance. Students also will review basic principles of metallurgy; mechanical properties; microstructures; thermal fatigue, stress and strain; effects of alloying elements, alloy chemistries and premium quality specification of steel; heat treating; distortion; die finishing; EDM; stress relief; surface treatments; and welding.

Materials
Care & Maintenance of Die Casting Dies
Recommended Procedures for H-13 Tool Steel
Handouts

Instructor
Henry Bakemeyer

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EC-503 Die Coating and Surface Treatments - REGISTER

A one-day course focused on the fundamental principles of coatings and surface treatments for die casting dies as well as repair and removal techniques.  This course is designed to provide a basic understanding of various coatings applicable to die components by covering topical areas such as coating processes, structure, properties, application, and characterization and evaluation of coatings.  Current state-of-the-art commercial and experimental coatings are presented and methods for optimizing coating architecture are addressed.

Materials
Die Coatings for Die Casting Dies

Instructor
John Moore

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EC-506 Engineering Die Casting Dies  - REGISTER

A two-day program dedicated to providing the process, techniques and references on how die casting dies should be designed to perform the functions required.

Workshop Summary

The die casting die has four basic functions: 1. To hold the molten metal in the shape of the desired casting; 2. To provide means for the molten metal to get into the space where it is to be held in the desired shape; 3. To remove heat from the molten metal to solidify the metal; and 4. To provide for the removal of the solidified casting. The overall goal is to design a die that will produce high quality castings efficiently and that is based on sound economic principles.

This course is targeted to the die casting tool designer, engineer, toolmaker and others involved in the design, construction and use of die casting dies. The course offers an understanding of what should be included in the die casting die design. The course begins with a tooling design philosophy and evolves into all the major systems that must be included in the die. Topics include parting line determination, die cavity placement and machine size requirements, dimensional requirements and capabilities, metal flow and gating considerations, heat flow needs, ejection and material requirements.

Materials
Designing Die Casting Dies
Handouts

Instructors
Henry Bakemeyer
Ed Herman
Scott Kirkman

Don Tremblay
Mike Ward

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EC-514 Gating Design  - REGISTER

A two-day program devoted to understanding and implementing a proven process for designing and calculating effective gating based on the specific feature of the die, the casting and the power performance of the machine.

Workshop Summary

Gating is central to die casting technology. There is perhaps no skill more important to a die designer, a process engineer or anyone involved in the process, than the ability to design an effective gate for a die casting die. This course provides an understanding of the theory behind gating design but focuses on a practical step-by-step process to design effective gating.

Five basic rules for gating are emphasized. A step-by-step procedure includes casting, gating and machine performance considerations. Basic topics of the course include gate location, gate velocity, gate area, runner design, chisel gates, fan gates, tangential gates and machine compatibility. Careful attention is paid to the methodologies and details of calculations including the use of calculators, spreadsheet templates and the gating slide rule.

Materials
Gating Die Casting Dies
Handouts

Instructors
Ed Herman
Scott Kirkman
Mark Osborne
Bill Walkington
Mike Ward
Ed Wrench

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EC-515 Die Casting Defects  - REGISTER

A two-day program devoted to understanding and identifying the probable causes of defective die castings and to determining and implementing solutions that minimize or eliminate the effects of the problem.

Workshop Summary

Defective die castings are quality deviations that must be corrected to meet the quality requirements of the customer. Defects are serious issues that are usually traceable to process settings and/or metallurgical problems. The good news is that most of them are correctable through operations control and process control. The purpose of this course is to provide useful information, skill and techniques to those individuals charged with the responsibility for process settings and production of quality castings.

The course is organized under four categories: 1. Process factors that control many defects, especially those concerning surface finish, cold flow and non-fills; 2. Metallurgy issues associated with defects. While all metals are covered, there is a special emphasis on aluminum; 3. Identifying defects and diagnosing causes; and 4. Troubleshooting guide studied by type of defect in order to swiftly take the appropriate action.

Materials
Die Casting Defects-Causes and Solutions
Die Casting Defects-Troubleshooting Guide

Instructors
Henry Bakemeyer
Darren Christiansen
Ed Herman
Scott Kirkman
Bruce McFadzean
Don Tremblay
Bill Walkington
Mike Ward
Ed Wrench

John Wronowicz

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EC-606 Product Design  - REGISTER

A one-day program dedicated to understanding the die casting option and the unique capabilities and advantages that die casting brings to the metal forming market. The workshop also focuses on the principles, concepts and techniques needed to optimize the design of die casting products.

Workshop Summary

This course is targeted for the die casting process, tooling, sales and quality engineers. The purpose of the course is to help the die casting professional better counsel the customer and/or to take a customer’s functional design and make it into an operational and economically viable die casting. The course describes how to analyze the product’s function in service and from those requirements, select the alloy, develop the casting configuration, establish the economics of production and determine the best prototyping method. The evaluation of alternative designs, alternative processing and alternative processes also is discussed. The course includes designing for machining, assembly, fastening, surface finishing and treatment and castability.

Materials
Product Design for Die Casting

Instructors
Henry Bakemeyer
Ed Herman
Bruce McFadzean
Jerry Wilkey

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EC-700 PQ2 - REGISTER

A one-day program tying the machine power available with the die and process parameters.

Workshop Summary

Does your die casting machine have the power to run the proper process to produce high quality castings? This course will provide the die caster with the knowledge of fill time and Bernoulli’s equations and how variations in shot sleeve size affect the power of the machine. It reviews optimization of the die cast machine and process parameters required to produce high quality castings.

Materials
PQ2 Machine Power and Die Compatibility

Instructors
Henry Bakemeyer
Bill Walkington
John Wronowicz

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EC-710 Computer Modeling - REGISTER

A one-day introduction to the uses and applications of computer simulation in die casting.

Workshop Summary

The course will illustrate and educate the participant about the benefits of using simulation, the types of problems that can be addressed, the human and technical resources needed to succeed with simulation and some of the pitfalls that can arise. The emphasis is on applications and benefits of computer simulation to process engineering and die design. The course does not focus on how to do computer simulation. It also does not address the theoretical and technical issues that underlie computer simulation.

Materials
Handouts

Instructors
Al Miller

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EC-806 Die Casting Cost Estimating - REGISTER

A one-day course explaining how to organize various cost factors in the manufacturing of a die casting and how to summarize and organize the data for management and marketing.

Workshop Summary

The focus of the course is to provide the most accurate cost estimates through the use of real manufacturing data. Students in this course will learn to use plant history to predict future performance through the use of group technology. They also will learn to calculate accurate machine charge rates based upon real capital asset values and real manufacturing costs. Die casting companies using the principles taught in this course will be able to more accurately assess financial weakness and opportunities.

Materials
Die Cast Cost Estimating

Instructors
Ed Herman
Scott Kirkman

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EC-902 Operating the Die Casting Machine  - REGISTER

A one-day program detailing the basic die casting setup, startup, warm-up and shutdown.

Workshop Summary

To a large extent, the die casting industry depends on the skill of the machine operator for efficient production of high-quality products. The effective machine operator understands the basic function of the process, the proper care of the die casting machine, die setup, recognition and control of basic casting defects, and the procedures that ensure his/her personal safety. Because of the high mobility of the labor market, it is frequently necessary to train new machine operators.

Materials
Operating the Die Casting Machine

Instructors
Henry Bakemeyer

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EC-908 Die Casting Machine Safety  - REGISTER

A one-day program to familiarize students with various safety topics and safe work practices specific to the die casting facility and the equipment used in the die casting process.   Topics relative to potential hazards associated with die casting machine and its ancillary equipment such as linkage areas, die cast tooling, rotating and moving equipment and working with molten metal are included in this course.

Workshop Summary

Safety is important in the operation of die casting equipment. Employee morale is best in a safe working environment. The quality of employees available to a plant and the quality of their output certainly is influenced by the environment in which the employee must work. Safety has an economic impact in terms of lost wages, the costs of compensation and hospital and medical expenses. High employee injury rates result in lost production and missed detail on construction and guarding of the die casting machine and correct practices in its operation. Specific topics, such as linkage areas, rotating couplings, safety ratchet pawls, ejector plates, core slide springs, spray guns and casting extractors, are included in this course.

Materials
Die Casting Machine Safety

Instructor
Henry Bakemeyer
Jerry Wilkey

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For more information on NADCA's Educational Programs please contact: EDUCATION DEPARTMENT