The Zinc Die Casting Process

An integral part of the NADCA education program, this book provides a better understanding of the zinc die casting process than you might get from the normal sequence of NADCA courses and texts. It provides an understanding on the zinc die casting cycle, with in-depth information on the die casting work cell, dimensional tolerances, and set-up, operation and control.

TABLE OF CONTENTS

Preface

Chapter 1 Introduction

Chapter 2 Alloys

Alloy Characteristics
Properties

Chapter 3 Metal Melting & Handling

Alloying
Melting & Holding
Safety
Reference Material

Chapter 4 The Zinc Die Casting Cycle

Chapter 5 The Die Casting Work Cell

Die Casting Machine
Holding Furnace
Die Spray System
Die Temperature Control System
Casting Removal System
Quenching & Transport
Trimming
Recycle Trimmings
Process Controls
Inspection
Robustness of Ancillary Equipment
Miniature Die Casting Machines

Chapter 6 Zinc Die Casting Tooling

The Parts of the Die
The Cast Shot
Die Steels
Sprues
Gating Design
Die Cooling
Ejection
Multi-Slide Dies
Chapter 7 Set-Up, Operation & Control

Set-up
Operation
Control
Die Casting Process Variables
Conlxol Methods
The Process Variables

Chapter 8 Dimensional Variation & Tolerances

Tolerances
The Die
The Process
Scale Sensitivity
Flash
Parting Lines & Insert Seams
Ejector Pin Marks
Miniature Die Casting

Chapter 9 Casting Quality

Surface Quality
Porosity
Quality Strategies

Chapter 10 Post Casting Operations

Trimming
Machining
Surface Preparation
Coating
Assembly

Chapter 11 Customer/Supplier Relations

Costing for Risk
Sophisticated Engineering
Die Caster-Customer Relationships Die Caster-Supplier Relationships

Appendix A: Shot System Performance

The paz Diayam
Shot-System Instrumentation
Transducer Installation
Instrumentation Calibration & Checkout Interpretation of Shot-System Data Determining PQ2 Diagram for a Specific Machine Gooseneck f Nozzle Characteristic Line

Appendix B: A Survey of Dimension Tolerance
Capabilities of North American Die Casters