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    13 views4 pages

    NADCASur Fin 4 DC

    Uploaded by

    sobheysaid

    Copyright:

    © All Rights Reserved
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    of 4
    Page 1 of 4 Document No, 023 trom the Die Cast Design INSTANT FAX LINE ©1996 oiecastng evelopment Cound SURFACE FINISHING FOR DIE CASTINGS A guide to surface treatment systems for protection, decoration and improved performance of die cast product components Many die cast products are put into use with no operations performed other than casting and trimming. A knowledge of recommended die casting surface finishing alterna portant to the product engineer and specifier when a specific finish is required, however, to guide die casting alloy selection itself. Surface treatment systems are generally ap- plied to die castings for one or more of the fol- Towing purposes: mt Provide a decorative finish Forma protective barrier against envi ronmental or galvanic corrosion Achieve pressure tightness if intercon- nected subsurface porosity is prese Improve resistance to wear Even when a die casting requires no further surface treatment for decoration, protection or improved performance, a deburring opera tion is almost always recommended. This step, removes any flash, burrs, sharp or ragged ‘edges that might remain after trimming, to fa- cilitate handling and any further finishing treatments, Mechanical, chemical and thermal deburring techniques are available, with vE- bratory deburring the most con —— Surface Treatment Systems Final finishing systems that offer the highest performance levels and are specified most fre- quently for dic castings are discussed here and summarized in the table on page 2. Decorative Finishes ‘Three types of decorative surface treatments are used on die castings: painting. plating, and right finishing other than by plating, Decora- tive finish quality largely depends on casting Fig. 1. The aluminum die casting fora computer printer heat sink, shown aseast on let as black anodized 10 provide conesion protection and tear resistance surface quality. Bright chrome and paint sys- tems that produce high luster or gloss require a high-quality surface. Systems that produce a textured finish are much less sensitive to sur- face quality. Therefore the die caster must know the precise surface quality and finish re- quirements to apply appropriate process con- trols, perform required die maintenance, and roduce secondary operations. Bright finishes, such as chrome-plated hard- plating, and intermediate buffing during sue- plat Matte finishes, typ: ically used for furniture and luggage, are achieved by sand blasting, grit blasting or scratch brushing followed by a clear lacquer Scratch brushing develops smooth line tex tures ora satin finish, Textures such as stip- ples and grain can be cast into the surface (sce illustrations on page 2), provided that the textured surface is generally oriented perpen: dicular to the direction of die draw. Die castings that are to be electroplated must be designed to accommodate the electr cal current density patterns that characterize the process. The complexity of the casting and the shape of features can affect current distribution and hence plate thickness. Good uniformity is achieved on gently curving con: vex surfaces. Comers, edges, fins, ribs and similar protruding features concentrate cur- rent flow and receive more than the average deposition of plated metal, Recessed features, such as grooves, serrations, holes, concavities and deep recesses, receive less than average (Gee illustrations on page 2). Electroplating requires successive steps of immersion in plating solutions and rinsing. All casting features, particularly deep recesses, must be designed so that plating solutions will readily drain. The castings must also be de- ‘signed so that they ean be buffed and racked ‘economically. Process controls can help to equalize plate thickness. However, the most effective means of achieving good distribution at minimum cost Is to follow recommended design proce- dures for configurations and orientation of features. Die castings can be painted like ferrous and nonferrous wrought and sheet products. How- ever, when exacting standards for a color. Prepared for (OEM designers, specitiors cand purchasers by the Discassting Development Counc, a Bulletin No. 4 Page 2.0f 4 Document No. 023 from the Die Cast Design INSTANT FAX LINE. ©1995 Decest Develoorant Cound —EE Surface Treatment Systems for Die Cast Parts Improved Design. Easy toplate uniform, espe- tally where edges are rounded Flat Surface ID Poor Design === Design. Use ‘015 nin. crown to hide undlations, caused by uneven butting Sharp Angled Edges = 3 —J Improved Design. All ‘edges should be round: ‘ed to avoid excessive ‘edge bull up. PURPOSE ALUMINUM MAGNESIUM ZINC ZA Decorative Paint Paint Paint Paint flalsh Polish/Epowy Plate Plate Plate @Zas, 24.12) Plate Chromate Chromate Chromate Powder coat Phosphate Phosphate Phosphate Environmental Paint Paint Paint Paint ‘or galvante Anadize Anodize Chromate Chromate corrosion Chromate Conversion Anodize Anodize barrier nidte coat dite Inidite Filan seal Impregnate Impregnate Impregnate “impregnate surface: ‘subsurface Improve wear Hard anodize Hard anodize Hard chrome plate Hard chrome plate rrealstance Hard chrome plate G8, 2812) match with adjacent dissimilar materials must be met, the paint may have to be specially for- mulated to achieve the desired result. Color match, surface preparation and priming vary depending on the alloy and application. Protective Barriers Die casting alloys are relatively active metals with a high potential to react chemically with the atmosphere, primarily water and airborne pollutants. The reaction forms a tight surface Coating that seals the surface and retards fur- ther corrosion. The coating builds up at a pro- gressively diminishing rate, developing an ef- fective barrier that frequently requires no ad- ditional corrosion protection, even in moder- ately severe environments, Factors that affect atmospheric corrosion can be managed through quality control and design specification, when designer and die caster interact in a simultaneous engineering program. Alloy purity is especially important to the corrosion resistance of magnesiuin, zinc and ZA die casting alloys. Chromating is one system of surface treat- ‘ment that is often applied to aluminum, mag- nesium, zinc and ZA die castings as a corro- sion protection system or a base for paint or

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