Basics of High Pressure Die Casting

& Die Maintenance

Rakesh Ghag
Chief Manager
Tool Management Services

1 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Cold Chamber Die Casting

DIE CASTINGS are produced

by forcing molten metal under
pressure into metal moulds
called dies.

Animated Video

Die Casting Process Video

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 Phases in Die Casting
• Taking the liquid metal from Sleeve to the in-gate at slow speed!
Called “First Phase”

• Filling the mold at high speed! Called “Second Phase”

• Compacting the liquid metal of the mold at high Pressure, during

solidification! Called “Third Phase”

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 Objective of 1st Phase
• When the plunger moves the liquid metal towards the
mold, the air occupying vacant space of the mold is
pushed ahead by the moving metal towards the mold.
• Most of the air then finds the exit through the air vents
(overflows) till the liquid metal fully occupies the runner
and in-gate profile. This brings about an ideal situation.
• In the absence of air, the runner is full of liquid metal
limiting the air content to the cavity space only.

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 Internal View at 1st Phase

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 Objective of 2nd Phase
• This is the mold filling phase. It happens at high speed of
injection plunger.
• When the metal is dragged to the in-gate plane by the
first phase what lies ahead is the air of the entire mold
cavity.
• The second phase is actuated at high plunger (effectively,
metal speed). The flowing metal must drive away this air
completely to occupy the mold contours.

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 Steps of all 3 Phases

Fill ratio = ( Shot volume / Active shot sleeve volume ) X 100

Shot volume = Volume of Biscuit + Runner + casting + Overflows
Active shot sleeve volume = Plunger area X active shot sleeve length

Machine fixed platen

Pouring location
Parting line
Plunger

Biscuit

Active shot sleeve length

Plunger starting point
Spreader Distance from platen to spreader
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 Objective of Intensification - 3rd Phase
• This is the pressure intensification phase and is actuated by
the intensifier of the machine.
• When the mold is completely filled and the metal starts
solidify from mold-wall inward, an intensified pressure tends
to push the liquid metal through the liquid core canal and
feeds the portion of solidifying sections.
• The extent of this “feeding” is, however, limited and for this
reason the casting layout must be such that the thicker
sections of the casting are nearer to the in-gate.

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 Objective of Venting

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 Objective of Cooling in HPDC

• The term “cooling” in die casting is a misnomer. It

is never intended to quench the die.
• It is only intended to maintain constant
temperature of the die so that the thermal
equilibrium is maintained or in other words the die
runs at a constant temperature, shot after shot.
• Reduction of thermal shocking effect increases the
die life substantially.
• To bring about the best results, it is best that the
method of cooling, medium of cooling and location
of cooling channels are carefully selected at the
design stage itself.
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 Cycle Time
• Total Cycle Time in a PDC process can be divided in 14 parts
Sr Activity Time (Secs)
1 Ejector Retract                                                  
2 Core In     
3 Machine Close      
4 Machine Lock    
5 Pouring       
6 Injection    
7 Solidification                       
8 Decompression    
9 Machine Open       
10 Core Out     
11 Ejection     
12 Casting Extraction         
13 Spray          
CI Ring placing
14 (optional)                                                  
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 Role of Die Coat (Spray)
• Release Agent
• Barrier Between Molten Metal and Steel
• Lubrication
• Maintaining Thermal Balance
• Metal Flow Promoter
• Improve Part Surface Quality

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 Narrow die temperature range

Adhesion process of Water based DL

Collision Wetting
Water

Die surface
Drying
Oils

Water dries, and the main components adhere to the

die surface by the heat of die surface. 　　　　　　

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 Narrow die temperature range

When die temperature is low,

Water can not dry

Die surface
Because water doesn't evaporate on the surface, it isn't
concentrated, and the main components don't adhere.

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 Narrow die temperature range

When die temperature is high, Insulating vapor layer

Die surface
Die lube is rejected when it is short of collision energy
by insulating vapor layer.

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 Typical HPDC Die

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 EJECTOR BACK PLATE
Elements of a HPDC Die
EJECTOR GUIDE
EJECTOR PLATE CHILLVENT MOVING DIE
INSERT COREPIN

HOUSING
FIXED DIE INSERT
SIDE

WATER MANIFOLD

FINGER PIN

BUBBLER

LEADER
BUSH

EJECTOR PIN
SPRUE BUSH
MOVING DIE BLOCK SLIDER
DIFFUSER LEADER PIN
ASSEMBLY FIXED DIE BLOCK
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 Elements of a HPDC Die
Core Pin
Material Hot Die Steel
H13 Grade
Function Forming Holes in
the component
Points to Bend
Check & Breakage
Correct
Profile Damage

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 Elements of a HPDC Die
Ejector Pin

Material Hot Die Steel

H13 Grade
Function Ejection of
Component from
Die
Points to Bend
Check & Breakage
Correct
Wear & Tear
Scoring

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 Elements of a HPDC Die
Sprue Bush
Materi Hot Die Steel H13
al Grade
Functio Positioning die on
n machine & Form a
Feeding Channel
Points Metal Sticking
to Crack
Check
Water Leakage
&
Correct Scoring
Flash

20 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Elements of a HPDC Die
Diffuser
Materi Hot Die Steel H13
al Grade
Functio Form Feeding channel &
n Direct Molten metal
Points Metal Sticking
to Crack
Check
Water Leakage
&
Correct Scoring
Flash

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 Elements of a HPDC Die
Insert
Materi Hot Die Steel H13
al Grade
Functio Component Forming
n
Points Metal Sticking / Soldering
to Crack
Check
Water Leakage
&
Correct Scoring
Flash

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 Elements of a HPDC Die
Side Core / Slider
Materi Hot Die Steel H13
al Grade
Functio Forming Undercuts
n
Points Metal Sticking
to Crack
Check &
Sticking in Slider
Correct
guides
More Clearance
Flash
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 Elements of a HPDC Die
Hydraulic Cylinders
Materi Standard
al
Functio Movement of Side Core
n
Points Oil Leakage
to Stroke Length
Check
Fitment with mating part
&
Correct Smoothness in movement

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 Elements of a HPDC Die
Die Housing / Mold Base
Materia C45 / EN8 / EN9
l
Function Holder for all die
elements
Points to Parallelism
Check & Eye Bolts Tapping
Correct Depth
Blue Butting of Inserts
& Sprue Bush
Blue Butting of Sliders
& Diffuser
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 Elements of a HPDC Die
Moving Core Sub Assembly

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 Elements of a HPDC Die
ydraulic Cylinder & Bracket Assembly

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 Basics of Die Maintenance

Rakesh Ghag
Chief Manager
Tool Management Services

28 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Need for Die Maintenance
Inherent Reliability

• Reliability – Probability that no problem will occur during a

given period

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 Factors Affecting Die Life

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 Contributors

Steel / Heat Machining / EDM

Treatment • Careful Machining
• Selection of Steel • Avoid Sharp Corners
• Heat Treatment • White Layer Removal
• Surface Coatings –
Nitriding, Coatings etc

Design & Die Caster

Construction • Pre Heating
• Minimal Spraying
• Thermal Layout
• Die Maintenance
• Layout of Cooling System
• Periodic Stress Relieving
• Optimized Gating System • Tempering after Welding
• Ease of Ejection • Minimal Thermal Cycles
• Alloy Used

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 Thermal Balance
Very Important to have Complete, Constant & Precise
Thermal Control throughout the Die Casting Process

Design & Production engineers have to consider the

thermal loads that occur in production (in terms of thermal
mass & cycle time) and ensure that the die faces do not
overheat.

32 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Balance
• Heat Input Factors
• Cycle Time
• Component Thickness
• Component Fill Time
• Melt Temperature
• Heat Out Put Factors
• Cooling Lines
• Spray

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 Types of Die Maintenance

Routine Die Maintenance

Usage Based Die Maintenance

Condition Based Die Maintenance

Breakdown Maintenance

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 Routine Die Maintenance

• Routine Maintenance is done after every 2500 to 3500 shots of a PDC Die. It is
done to ensure smooth working of the die during regular production

• Activities Carried Out in Routine Maintenance are

• Polishing of the Catching Prone Areas
• Cleaning of Cooling Lines
• Cleaning and Stoning of Moving elements like Sliders, Tunnel Cores,
Ejector Pins etc.
• Flash Removal from Parting faces and Stoning
• Application of Graphite Lubricant on Moving elements
• Limit Switch Mechanism Check and Tighten if required
• Moving Cores Sub Assembly Check and tighten if required
• Sprue Bush and Diffuser Cooling Line Cleaning
• Polishing of Sprue Bush ID on Lathe
• Stoning of Runner Area in Diffuser

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 Usage Based Maintenance
• Usage Based Maintenance Maintain the die in Good Condition and Prevent
Breakdown in production. It is done after
• Initial 2000 shots
• 5000 to 10000 shots
• Thereafter every 20000 shots

• Activities Carried Out in Usage Based Maintenance are

• Stripping of the complete Die
• Inspect all Moving Elements of Die for Wear
• Inspect all Cooling Elements of Die
• Die Penetrant Test of Major Die Elements
• Stress Relieving of elements which come in contact with Molten
Aluminium
• Polishing of All Component forming elements after SR
• Replacement of Clogged Cooling elements
• Replacement of Worn out Ejector Pins
• Replacement of Core Pins which are likely to fail in production
• Carbide coating of Solder prone areas (especially near the gate)
• Plus Other Routine Maintenance Activity

36 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Condition Based Maintenance
• Condition Based Maintenance is done to Eliminate the Causes of Accelerated
Deterioration and to improve Die Condition

• Activities Carried Out in Condition Based Maintenance are

• Replacement of Distorted or Soldered Sub Inserts
• Replacement of Core Pins or Other Die elements after the specified life
• Re Spotting of the Core & Cavity to minimize flash
• Welding of Cracked Areas
• Welding in Heat Check mark areas
• Sub Insert Fitting in Areas likely to fail in near production lot

37 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Breakdown Maintenance
• Breakdown Maintenance is done to Repair or Replace the die elements which have
failed during production
• This is not the ideal condition in any DC shop as it causes production loses & fire
fighting.

• Activities Carried Out in Breakdown Maintenance are

• Replacement of Failed Die Elements
• Welding of Failed Die Elements
• Sub Insert Fitting in Crack or Failure prone areas

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 Wear & Tear of Die Elements

Forced Deterioration Natural deterioration

Varying Level of
Compliances
• Thermal Stresses
 Periodic Maintenance • Wear of Moving Elements
 Pre Heating & Die
Cooling Practices
 Excessive / Imbalance
Machine Tonnage
 Assembly
 Mickey Mouse Fixes

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 Observations during die maintenance
• Examples of problems faced in a Aluminium PDC Die Due to Thermal Stresses

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 How do heat check marks start?

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 Intermittent Stress Relieving
Process for Stress Relieving of a PDC Die
1. Load at 200 / 250 C
2. Heat up to 550 / 560 C
3. Hold at 550 / 560 C for 2 hours (For a 800 ton Crank Case Die.
This time will change depending on Die Cross section
4. Furnace cool to 430 C maximum and then remove from furnace
and air cool

Frequency for Stress Relieving

1000 to 2000 shots
5000 to 10,000 shots
Repeat for each additional 10,000 to 20,000 shots

42 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Nitriding
• After the solidification is completed, the dies are often sprayed with lubricants to
cool the die surface and to facilitate part removal
• When the lubricant layer washes out or is not properly applied, the molten cast
metal comes in contact with the die surface resulting in micro-welding or
soldering
• Molten aluminum alloy reacts with the die steel forming complex aluminum-iron-
silicon intermetallics and resulting in soldering of the cast metal to the steel
substrate

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 Nitriding

Nitrided Layer forms a

sandwich between
Die Surface and
Molten Aluminum
preventing them to
come in contact with
each other

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 Caution for Nitriding

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 Carbide Coating at Intervals

• Carbide Coating is done in areas that are prone to soldering and catching
• These are the areas opposite to gate and some high rise locations in the die
• Polish the area and clean the stuck Aluminum
• Deposit Carbide Coating on the selected area.
• Light Polishing of the area with Emery Paper

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 Teflon Tape Usage

Ending point Starting point

Leave 2
threads and
start wrapping
Teflon tape
Use 6mm width Teflon tape for Threads
Water Cooling Connectors

Use 12mm width Teflon tape for

Hydraulic Connectors

47 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Cooling Line Cleaning at Intervals
• Dismantle the Die and take insert to water line testing
zone

• Check the hole ID

• Using Hand Drilling Machine insert drill with 1mm less

diameter
• Start drilling and push the Hand drilling in cooling
hole

• Keep on reciprocating till the drill touches hard face

of the die

• Remove the slag and other dust from the drill tip

• Flush the hole with high pressure water

48 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Welding in a HPDC Die
• Job Cleaning and Drying
• Pre Heating of the Die Element to 350 Deg C. (Do Not Weld Below 350)
• Use Either ASSAB QRO90 or Weltrode 7100 TIG Welding electrodes
• Cover the Job in Glass Wool or Asbestos Sheet. Leave the area to be welded Open.
• Weld the area in intervals between runs
• After completing Welding Cover the Jobs with Glass Wool or Asbestos Sheet
• Allow SLOW Cooling of the Job
• Do Stress Relieving after welding
• Do Machining or Hand Matching of the Welding area
• Monitor the Welded Area after every 1000 shots

49 I Godrej Tooling I Tool Management Services I HMSI 4F – On Job Training – June to November 2016
 Welding in a HPDC Die

Welded Component
area for Heat Check
Marks

Welded gate
area

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 Approach towards Die Maintenance
• Measure for Tool Performance which is periodically
determined and improved through failure analysis
1. Mean Time To Repair
2. Mean Shots Between Failures
3. Number of Minor Stoppages
• Root Cause Analysis of each problem is done based on
1. Inputs from Production Shop
2. Scrutiny of Tool using Customised Check lists
3. Machine Condition and parameters wrt to Design &
Flow Analysis

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 Die Maintenance History
Documentation
• Die History Card

• Preventive Maintenance Record

• Last Casting Report

• Die Repair Request Sheet

• Kaizen Idea Sheet

• Maintenance Prevention Sheet

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 Tool File Records

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 Inputs from Design Review Meetings

• MP Sheets need to be made at the end of each project.

This facilitates actions on OFIs
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 Tool File Records

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 Tool File Records

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 Tool File Records

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 Actions on Maintenance Feedback

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 Close Loop System Essential

Design

Die Manufacturing
Maintenance

Production
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 Thank You for your time.

Questions Please……

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