1: From what material should hot chamber zinc die casting nozzles and noses be made?

The material that is most widely specified is H-13. This is the same
material that is used for most cavity blocks and inserts. Its chemical
composition resists washout, and its mechanical properties withstand the
severe compressive loads associated with zinc die casting.

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2: What material is recommended for plunger rods?

Plunger rods for cold chamber machines are produced from AISI 4150
HT. This material possesses high mechanical strength, good toughness
characteristics, and can be machined in its pre-hardened condition (28-32
Rc). Due to the high mechanical loads associated with cold chamber die
casting, use of a lesser quality material results in unsatisfactory plunger
rod life.

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3: Why do my nozzles wash out?

The primary cause for nozzle washout is excessive nozzle temperature.

While the casting temperature of zinc alloy is usually 800 degrees F,
nozzles are often heated in excess of 1000 degrees F. This excessive
temperature is the primary cause for nozzle washout. Other contributing
factors are the type of alloy being cast, and high aluminum content.

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4: What are the differences between tool steel and cast iron plungers?

Plungers for zinc die casting are commonly produced in either cast iron,
or tool steel (H-13). Cast iron plungers can be produced in a near net
shape, reducing the amount of machining required to produce a
functional part. However, they are susceptible to mechanical failure due
to the nature of the casting.

Tool steel plungers are produced from bar stock, and require extensive
machining to produce a comparable finished part. The mechanical
properties of the tool steel plunger are far superior to those of cast iron,
which usually justifies the increased cost. Heat treating can increase the
durability of the part even further.

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5: How much clearance is required between the plunger and the gooseneck in a
conventional hot chamber zinc machine?

The general rule for clearance between the plunger and the gooseneck
sleeve for a conventional hot chamber zinc machine is .002" per inch of
plunger diameter.
For example, a 2-1/2" plunger would have .002" x 2-1/2 or .005"
clearance. This clearance allows the plunger to move freely in the sleeve,
 while the rings seal the plunger and provide the necessary injection
pressure.

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6: Are there standard shot-end parts for my machine?

While there are standard items for the shot-ends of various casting
machines, most die casters benefit from customizing the shot-end tooling
to the particular job they are running. In many cases, shot-end tooling is
an extension of the gating system, and will have a definite impact on die
performance.

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7: How can we recondition the sealing surfaces of our nozzles?

The refacing of nozzles is done in a lathe. The best method is to use a

single point tool, sweeping it through an arc to produce the proper radius.
(See photo) Form tools can be used, but are susceptible to chatter. It is
crucial to have a good surface finish to ensure a good seal.

Another important point to consider when resurfacing nozzles is that

although the outside of the nozzle may look fine, the nozzle may be
washing out from the inside. Remove nozzles from the machine while
still hot, and drain any zinc from the nozzle. This will allow inspection of
the inside of the nozzle for any washout that may have occurred. (See
photo)

Brach Machine, Inc. can reface nozzles for you at a fraction of the cost of
a new nozzle. We inspect the I.D. and mark each piece, in order to track
how many times a nozzle has been in service. Please call for details.

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8: What are the various methods of supplying water to the plunger tip in a cold chamber
shot end?

There are several methods of supplying water to the plunger tip. Most
shot rods have a center hole drilled through them, allowing the insertion
of a baffle tube. Water flows into the plunger tip through the tube, cools
the plunger tip, and flows out in the area between the tube and center
hole. This tube is usually made from thin wall brass or stainless steel.

With some of the newer high velocity shot-ends, customers have

experienced problems with this type of baffle tube breaking off or
loosening. This problem can be overcome by drilling two separate holes
in the shot rod. These holes act as independent channels for cooling
water, and have no separate parts that can come loose while in use. (See
example)

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9: How can I minimize the cost of re-sleeving my gooseneck?
Removing any nozzles, heaters, thermocouples, and excess zinc before
you ship the gooseneck will reduce additional charges. These parts are
much easier to remove while the gooseneck is in the machine and up to
operating temperature.

In addition, it is important for the customer to evaluate the condition of

the gooseneck before it is shipped to us. If the gooseneck cannot be re-
sleeved, a minimum fee for "de-zincing", inspection, and return freight
(if applicable) will be charged.