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Die Casting Methods and Applications
Die Casting Methods and Applications. To produce die casting for specific applications, the following variations on the basic process can be used. “Squeeze casting” is a method that yields high quality, dense, and heat treatable components. In this method, molten alloy is cast without turbulence and gas entrapment at high pressure. Another procedure is the “semi-solid molding”. Semi-solid metal billets are cast to give dense, heat-treatable castings with low porosity.
Sophisticated methods to automate the die casting process are used by modern die casters. These methods provide continuous quality control. Automated systems are used to lubricate dies or die casting tools and die casting molds. These systems are also used to ladle metal into cold chamber machines, and integrate other functions like quenching and trimming castings.
Microprocessors obtain metal velocity. They shot rod position and hydraulic pressure and other data. These data are used to adjust die casting machine process. This is to assure consistent castings shot after shot. These process control systems also collect machine performance data. These data are for statistical analysis in quality control.
One of the fastest and most cost-effective methods for producing a wide range of components is die-casting. To be able to maximize benefits from their process, it is important for the designers to coordinate with the die caster during the early part of product design and development. This way, issues affecting die cast tooling and production are resolved, while identifying trade-offs affecting overall costs.
For more information on die casting designs, there are a lot of websites in the internet that may help get insights and details. You may also find online various die casting companies that may help you with your die casting requirements.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Posted in Diecasting Process
Tagged Die Casting Company, Die Casting Process, die casting tooling
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Future of U.S. Manufacturing
We have all been exposed to the current doom and gloom about the state of manufacturing in the United States. We see the stories in the media about manufacturers shutting down plants and eliminating thousands of jobs. Young people today are seldom encouraged to look at manufacturing as a career choice. Should we all just abandon manufacturing and become part of the service economy? I don’t think so.
Looking at U.S. Census Bureau data for the 29-year period from 1977 through 2005, a whole different story is told, although with some downside as well. The number of people employed in manufacturing companies in 1977 was over 18.5 million but employment declined almost 29% by 2005 to just over 13 million. The number of hours worked by production operators also declined by the same amount to just over 18 billion.
This paints a distressing picture of a shrinking manufacturing sector, but there is an offset to this decline. Over the same period, the value added by manufacturing operations in the United States
increased 377% from $585 billion to over $2.2 trillion, and manufacturers’ sales increased 349%. The combination of increased value-add and reduced production hours results in the manufacturing value-add per production worker hour increasing by 530%.
What this data shows is that manufacturing is certainly not dead, and we should not be willing to just write it off. With sales up almost 3.5 times and the value-add up by a factor of 3.7 while employment and production hours decline, this is a story of productivity increasing, not manufacturing shrinking. Thomas Duesterberg, president and CEO of the Manufacturers Alliance/MAPI, in a recent issue of Quality Digest states that manufacturing value-add has grown sevenfold since 1947, the same as the growth of the nation’s gross domestic product.
There are two key drivers in this increase in productivity. One is the more widespread adoption of continuous improvement to make the manufacturing process more efficient, and the other is the increased use of capital. In the early 1980s, people became aware of the Japanese manufacturing technique called just-in-time production and started to learn about it. Today, more and more manufacturers are adopting lean as a business system and are using continuous improvement as a key driver of productivity increases in their businesses.
During the 29-year period of the Census data, capital investment in manufacturing companies increased from $51.9 billion to more than $128.3 billion, almost 2.5 times the investment in 1977. When you look at this in relation to the number of production hours worked, it’s an increase of almost 3.5 times from $1,945 per production operator hour to $6,729 per hour. This increase in the use of capital instead of production labor, along with the wider adoption of continuous improvement and lean techniques, has resulted in the reduction of manufacturing employment and production hours worked, while manufacturing company sales and value-adding work continue to increase.
This has also yielded much higher wages for the people still employed in manufacturing. The wages paid to production workers rose from just over $157 billion in 1977 to almost $337.5 billion in 2005. The average hourly wage (not including benefits) rose from $5.89 per hour to $17.70 an hour over this period. This is why we keep talking about manufacturing jobs helping create the middle class in the United States. These wages are much higher than the service sector.
What else does this data tell us? We are seeing higher skilled production operators now making higher-value products with much more capital-intensive equipment than in the past. The lower-value commodity consumer products are being sourced from low-cost countries. Having higher-skilled manufacturing workers using continuous-improvement techniques to increase productivity and using more expensive (and more capable) capital equipment contributes to lower manufacturing employment but higher value-add per employee and higher sales for manufacturers. This is not the story of the death of manufacturing in the United States, just one of change and continuous improvement.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Aluminum Alloy Casting
The Process of Aluminum Castings. Die casting is probably not a new term for you because everywhere you look; you will see parts and equipments that employed this process for them to be created. Now, aluminum is among the few metals that can be utilized in casting metals. These processes of aluminum casting are the following: permanent mold casting, die casting, investment casting, plaster casting, sand casting (include dry sand and green sand), and continuous casting. Some of the other processes in aluminum casting also include squeeze casting, lost foam, and hot iso-static pressing.
Basically, there are various factors that should be taken to account in the selection of a particular casting process specially in making a detailed aluminum alloy part. Among the most vital factors consist of:
* Quality factor.
* Feasibility
* Cost factor
When talking about feasibility, a lot of aluminum alloy castings may be done using any available methods but for general castings, this process is highly determined by the dimensions or the features of the design. Furthermore, the quality factor is considered as well. Be reminded that the term “quality” when applied to casting would refer to the degree of reliability as well as the levels of mechanical properties which include the strength and ductility. The act of determining the act is also important.
Aluminum castings are considered as easy process as compared to manufacturing other kinds of products but expertise is still needed because not all people can do it properly. In fact, good skill and reliable materials are compulsory in this procedure.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Die Casted Aluminum Hardware Handles
Die Casted Aluminum Hardware Handles. In creating large amounts of small to medium sized parts made from non ferrous materials such as tin, zinc, copper and aluminum based alloys, the best method to use is known as die casting. Die casting is a manufacturing process which can be very useful to most companies who makes automobiles, guitar amplifiers, house lighting and other products which need aluminum parts. Aluminum Hardware Handles are among those which can be created in a fast and efficient manner using die casting. Most companies prefer to use aluminum for these handles because due to their purpose, it takes a lot of beating overtime. Being pushed and pulled all the time, hardware handles need to be strong, and since aluminum is said to be as strong if not stronger than steel, it makes for a good candidate.
Also, Aluminum Handles will not only last longer compared to using other materials, they are cheaper as well. Aluminum can be harvested almost anywhere and in vast quantities, which is why they are cheap. But, how exactly does die casting Aluminum Hardware Handles work?
The first step that is taken in this process is to melt the aluminum. Once it is molten metal, it is then injected into molds which give the liquid its new shape. Using intense amounts of pressure which ranges from 1,500 to 30,000 pounds per inch, the liquid is forced into every cavity of the mould. When the molds cool down, the result is Aluminum Hardware Handles. The best part is that these handles have good surface quality, accurate dimensions and each product is consistent with the other.
Aluminum Die Casting Alloy
Aluminum Die Casting Alloy. Aluminum is one of the most common alloys used in die casting. Aluminum is also one of the many alloys that can undergo almost all the process in casting. Die casting is where the aluminum is mostly used. But pure aluminum casting is rarely produced because of the susceptibility of the alloy to cracking and shrinkage. This alloy is usually alloyed with silicon and copper because these two alloys can increase melt fluidity, especially silicon, and reduces ductility. Silicon can also reduce maintainability of the alloy and copper can increase the hardness. The combination of the three alloys can reduce corrosion. For better corrosion resistance, aluminum casting with lower copper should be used such as 360 and 413. Aluminum is also commonly used when it comes to electricity because of its conductivity and high temperature strength. Aluminum has many uses in today’s everyday lives from office to home to commercial uses and industrial uses.
Aluminum Die Casting also has high dimensional stability when doing complex shapes and thin walls. The typical applications of aluminum alloy are Alloy 380.0, A380.0, 360, 413, and 518.1. They are typically used for home equipment like lawnmower, dental equipment, street lamp housings, frying skillets, escalator parts, connecting rods, instrument cases, and marine and aircraft hardware. Alloy 518 is known to have the highest corrosion resistance but it has low fluidity compared to the other aluminum alloys. This is also usually the most expensive aluminum alloy because of the difficulty to cast.
Aluminum casting usually doesn’t undergo heat treatment but instead undergo metallurgical stabilization and dimensional treatment.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
