Courses

NADCA offers a full range of online and in-person courses focused on all aspects of die casting design
and production.

View Current Course Schedule  

 

Courses

EC-102 - Introduction To Die Casting

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

Corresponding Online Classes: Operator Training: Introduction to Die Casting & Safety on the Shop Floor
Operator Training: Understanding Metal Melting/Handling for Operators
Die Casting Machines & Dies
Die Casting Alloys & Fundamental Die Casting Defects & Safety

 

EC-106 - Geometric Dimensioning & Tolerencing

A one-day course devoted to familiarizing students, designers, and engineers with the fundamentals of Geometric Dimensioning and Tolerancing (GD&T). 

Workshop Summary:
This course will go through the fundamentals of Geometric dimensioning and Tolerancing (GD&T). It will start with BASIC Mechanical drawing and how drawings are constructed. Once good drawing practices are established, how to dimension a drawing will be reviewed. Then, starting with an overview of GD&T, we will review the rules that support GD&T. We will then go through all the GD&T symbols and their application. The course will present the way to read and interpret GD&T on a Drawing. The course will establish how to use and interpret datums, position Tolerancing and Bonus Tolerances. Finally, we will define the conditions of GD&T by reviewing examples of each of the GD&T symbols.

Materials:

NADCA Product Specification Standards

Corresponding Online Classes:

Geometric Dimensioning and Tolerancing: Mechanical Drawing
Geometric Dimensioning and Tolerancing: Datums and Tolerancing
Geometric Dimensioning and Tolerancing: Rules and Symbols
Geometric Dimensioning and Tolerancing: Dimensioning

EC-201 - Magnesium Die Casting

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

Corresponding Online Courses:
Introduction to Magnesium Die Casting

EC-202 Zinc Die Casting

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

Corresponding Online Courses:
Introduction to Zinc Die Casting: Advantages, Properties and Alloys
Introduction to Zinc Die Casting: Processes and Tooling

EC-205 Quick Die Change

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

Corresponding Online Courses:
Safe Reliable Die Clamping
SMED Motivation and Concept
SMED the Systematic Approach
SMED Analyzing and Improving

EC-211 Dimensional Repeatability

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

Corresponding Online Courses:
Dimensional Control Theory
Dimensional Control Example

EC-302/3 Metal Melting and Handling

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:

his 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:

Metal Melting & Handling

Corresponding Online Courses:
Safety and Alloys
Alloying Elements and Furnaces
Metal Handling, Treatment Method
Metal Quality and Casting Defect

EC-305 Metallurgy Of Die Casting Alloys

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

Corresponding Online Courses:
Die Casting Alloys
Performance of Die Casting AL Alloys
Enabling Tools for Alloy Development - case studies
Alloy Effects, Phase Diagrams, Microstructure
Impurities and Melt Treatment
Analytical Techniques to Assess Melt and Cast Quality, Alternative Processes

EC-406 Machine Maintenance: Hydraulics

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

Corresponding Online Courses:
Basic Hydraulics: What the Heck is “Hydraulics
Basic Hydraulics: Why do “Hydraulics” do what they do?
Basic Hydraulics: Fluid is PUSHED from the Reservoir into the Pump. Really.
Basic Hydraulics: Making Hydraulic Fluid Do the Right Thing
Basic Hydraulics: Contamination Control
Basic Hydraulics: Odds and Ends
Basic Hydraulics: That’s a Wrap!

EC-407 Mechanical Maintenance: Mechanics

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

Corresponding Online Courses:
Mechanical Maintenance & Evaluation of Die Cast Machine: Die Casting Machine Primary Mechanical Structures
Mechanical Maintenance & Evaluation of Die Cast Machine: Die Casting Machine Primary Dynamic Structures
Mechanical Maintenance & Evaluation of Die Cast Machine: Die Casting Machine Set-up and Maintenance

EC-408/9 Machine Maintenance: Electricity

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

Corresponding Online Courses:
Basic Electrical Theory and Meter Use
Control Components and Their Function
Understanding Control Circuits
Programmable Logic Controllers Function 
Maintenance Procedures for Electrical System
Troubleshooting Electrical Systems

EC-410 Process Control

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 2015 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

Corresponding Online Courses: 
Control Theory and Process Capability
Shot Parameters
Other Die Casting Parameters

EC-411 Die Casting Lubricants and Coolants

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

Corresponding Online Courses: 
Die Lubricants: Selection, Use and Evaluation

EC-413 Die Cast Problem Solving

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

Corresponding Online Courses:
Basic Statistics and Problem Solving Methods
Experimental Design Basics and Examples

EC-415 Thermal Design and Control

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

Corresponding Online Courses: 
Die Spray
Thermal Lines
Thermal Design Theory 
Die Design - Thermal Design Example
Thermal Control
Thermal Design Theory 2 
Thermal Design Example 2 

EC-420 Machine Systems

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

Corresponding Online Courses:
Shot System Components: The Shot Sleeve
Shot System Components: The Plunger Tip, Plunger Rod & Shot
Shot System Components: Operational Guidelines

EC-430 Process Monitoring

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.

Workshop Summary:

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

Corresponding Online Courses:
The Influence on Casting Quality
The Slow Shot
The Fast Shot
Shot End Monitoring 1 
Shot End Monitoring 2 / Shot End Control
Shot Parameters
Other Casting Parameters

EC-501 Die Material Metallurgy And Extending Die Life

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 

Corresponding Online Courses: 
The Quality of Steel
Influence of Process Parameters and Maintenance on Die Life
Applying New Technologies to Die Repair
Why Dies Fail and How to Prevent Failures?
The Effect of Softening, Residual Stresses and Stress Concern
Repair of Dies
Cleaning Techniques Used for Die Casting Dies
Die Preparation Before Heat Treat

EC-503 Die Coatings and Surface Treatments

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.

Workshop Summary:

 

Materials:

Die Coatings for Die Casting Dies

Corresponding Online Courses:
Surface Treatment and Coating Technology Used in Die Casting

EC-506 Engineering Die Casting Dies

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 in and out of the die cast cavity, including waterline placement for depth and length.  Design of ejection systems and die materials.    

Materials:

Designing Die Casting Dies

Corresponding Online Courses:
Design Considerations for 3 Plate Casting Die
The Vent
Slide Design Considerations
Cooling Line Placement in New Die Steels
Basic Die Casting Die - Holders and Locking
Basic Die Casting Die - Inserts and Fit 
Moving Cores 
Ejection 
Processing Aides 
Die Spray 

EC-514 Gating Design

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

Corresponding Online Courses:
Designing Runners, Overflows and Vents

EC-515 Die Casting Defects

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 root causes and corrective actions; 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

Corresponding Online Courses:
Introduction to the Causes of Porosity
Control Porosity with Processing Parameters
Design for Reduced Porosity
Predicting and Measuring Porosity
Reduce Die Soldering in Die Casting
Eliminating Flash Defects in Die Castings
Understanding Porosity
Casting Design
Die Design
Process Control
Flash Free Die Casting
Porosity Defects and their Causes
Surface Defects and Other Problems
Reducing Externally Solidified Products-Essential for. Structural Die Castings

EC-606 Product Design

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

Corresponding Online Courses:
Design for Die Casting: What features can and should be die
Die Casting Process: What is the die casting process?
Die Castings Defects: Where do they come from?

EC-700 PQ²

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

Workshop Summary:

How much gate area do you need to make a quality casting? Does your machine have enough power to provide a robust process capable of producing high quality castings? The PQ2 process provides a starting point for determining gate area, defining a process window, and fitting a machine to that window. Utilizing Bernoulli's equation to relate process variables to pressure and flow rate allow a designer to match a machine to the casting and optimize the process. Restructured in 2016, by Al Miller with the new Gating Equation, the process starts with the casting requirements and how it effects the process window and uses that to select the machine.

Materials:

PQ2 Machine Power and Die Compatibility

Corresponding Online Courses:
Introduction and Basic Principles
PQ2,the Operating Window, Machine Constraints
Calculations

EC-710 Computer Modeling

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

Corresponding Online Courses:
Die Casting Modeling Capabilities
FEA and FVA - The Different Modeling Approaches
State of the Art Die Casting Modeling Practices
Predicting Castability of Ultra-Thin Parts Using Simulations

EC-902 Operating the Die Casting Machine

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

Corresponding Online Courses: 
Operator Training: Die Casting Machine Components & the Die
Operator Training: How it Works - The Shot End
Operator Training: Why Shot Monitors are Important
Operator Training: Die Components & Their Functions
Operator Training: Everybody Is Involved in Die Setup
Operator Training: Proper Care and Treatment of Dies During
Operator Training: Recognizing and Controlling Flow Defects
Operator Training: Recognizing and Controlling Porosity
Operator Training: Eliminating Solder and Flash Defects

EC-908 Die Casting Safety

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

Corresponding Online Courses:
Basic Safety in Die Casting
Machine Maintenance Safety in Die Casting
Electrical Safety in Die Casting
Managing Safety in Die Casting