rola A871 e9] yortag7iesl Ba —aeet- ole wal 0 aso a a** Review of Die Casting Technology 1. Mo PFAEBE HAM BVS 7H MES HAS wae Az Sa do ve +e sas AAAS ASAE S Hole}, HS] cho] AA Be ds wae G+ Me gaol del teal ww, SELAe, ob, Fel Bol syn aed ag AZ $yo) Folxa Ye ¥2| 44) 3, Shot sleeved $@ FY Uo] 22 4.99 39) 84 om ae 6. Qe SHS SHEL S7iale} eh. 1849\44l] Sturgissof 9]2] THO] 72g 7) A17+ Sais Ue clays Az) BOB] Bey HLS lua eon AIFS 7a w (gooseneck style) 2] 2 #¥i(hot cham ber) to] 7)Al7} ROL a Ob Sh 7b Sa 3] Se Al ZIM ©1517) Al sRom] 1935 Wale Iu Ge Fe FRE MB AL a ¥i(cold chamber) tho] AAW 7) a7} AAS 7 HSU. 1959} AV Acurad?}at Be} 5. HES} AS} EGU EAP BAA AWS AAG (squeeze casting) $ 2% Yao) ol sava. 1981 do] = >} F 2} SY A}(Harvill Machine, Enc.) 7} #3 2 wi (horizontal hot cham- ber) late] SYS ReaeR FS 717] (Metal matrix) t ARE "Hse Aa)z + aesHpled Bees, UREd ARE (a) Y.T.im*, ZH. Lee ** AAG VPs We $Fo] AsoHe ol Fo} ayn ale, SEHD NE Fos Qa, co} 71 29 7A Re BAI 2, HD Se Sal aT wana ee. 2. M[7|2] CHO] FHA Aree} Ha AA] $2 oA Ale) Alse gs 3} BE 57) THOS UML al se Uh AR a, Sa, ASS Aes, ye] Sel. El = Chem-Trend A}7} Ab Se] Ag] e A) Fo] et MASE RL FBI BIS S7HO} Hola eH, 6] RApo Sapa HBS Aes 1 AMo) AFUs RIS AEs Saat az Ye ASSP ARIA ss} Fay ety ols Ae] tts] keh, Su] z]e}e] co] AAG Yds Vs, 3s, GH R aid 2) 4S BA] FAD Nom Brakgos ¥ Wola APRA] AAS BPs Wet. o} = Axo} "lFoyAy Yrts|ar ge A ce] ay AG FHS] PUES (tonnage, ¥ 24H) H1 o} Fold) aes} ulmal wel @ + ach ae HA FO} wh} Zo] v}sF] cho} AG vel 3 7A BASS Al SSAAS AMS AGA Awe Be ALS yea Veh we} 4 QS AB ASHE Pls] ho) AAD BUS IH] Fal VMAS sel7] ¥ Yeas Addn NSAI $98 AMS WE IS 7s} ach.jujo Vol. 10, No. 3 ‘The Journal of the Korean Foundrymen’s Society -165- EL. Sa de] AQ sual aa AA St B7h 2a gaiiey | ast) AGE AS WESTERN EUROPE 224,000 5% W, Germany 3,000 7 224,000 3% Italy 3,000 2 110,000 2 France 1,600 10 74,000 4% Spain 1,100 10 60,000 0% Uk 1,000 170,500 a Others 1,700 762,500 = TOTAL 1,400 = EASTERN EUPOPE Total 3,000 st 200,000 3% PACIFIC BASIN Japan 4,000 9 500,000 2% China 2,000 30 100,000 % Taiwan 400 7 30,000 8% Korea 300 8 20,000 10% Hong Kong. 40 10 20,000 5% Australia 180 2 12,000 3% Singapore 100 6 7,000 2% Others 500 2 25,000 1% Total 7,850 714,000 LATIN AMERICA Brazil 600 15 45,000 % Mexico 300 2 20,000 9% Others 300, 15 15,000 2% Total 1,200 80,000 2. n)R04|9} ho] AAG Mabe Die casting shipments( 1000s of tons) Metal 1963 | 1984 | 1985 | 1986" Aluminum, ae 32) 396 | 389 | 380 av 259 | ze | 2m | 265 Zine Ne 188 | 178 | 69 | 158 ar 109 | 10 | 1 | 85 ‘Magnesium 1% 45 (53 | 64 | 675 ah os | om | ris | 110 Source : American Die Casting Institute, "ef (8) Eh va F292) SH HOA A o} Eo) FO} 8 bs} ge] HRS] cho) AA 2 4ES ASA1d AA OSS] VT 19} $B f AS SAW ROE ASSO}, He H 5s} GE AS Mtl eet FAW ‘a} ol ape ofe} QlxH ee] Hl ats}o} gle. 6] HS BU qo] AAV LS FAs wash Bq HA ari, AS] Vy, He TAS WA REY FA THEY, MAE STR VAS ABE Md] Vo} FAIS RIF Neh. aay vo) PAGS SEAM), HH) 27) BSI a7) Fs Awad SSIs 4a FA wae Mal Polat BoycH= 186- wotagas tase 12a E3913 co) AAW Aas] aa Hot Chamber Machines Wht 4 10~208 | 2odel4el | 87idoH Hall a7dol (AAaiton) Ae Ae alae BrdAat Under 100 89 4 4 = uw 101-250 55 2 2 = 15 251-400 46 5 19 6 401-550 wv 12 4 = 551-700 4 4 = = = Cold Chamber ‘Machines Under 100 4 2 = - = 101-250 16 2 10 = a 251-400 48 ar a. = 6 401-550 86, 40 31 7 4 551-700 ua 104 Ea = uw 701-850 2 20 2 6 851-1000 19 u 4 a 2 1001 ~ 2000 22 9 8 = = Over 2000 2 = = = = Ba MasES 7A malas) pea (millions of $ delivered cost)” ABLUAAR 1977 1982 1987 Communication equipment Telephone /telegraph (aluminum & alloy) 92 66 10.6 Radio /TV communication equipment (aluminum & alloy) Bl m8 69 Electronic computing equipment (aluminum & alloy) 39.5 1044 220.3 (other nonferrous) - 86 11 Household appliances Cooking equipment(aluminum & alloy) 66 7 60.8 Laundry equipment aluminum & alloy) 11.6 a7 2.7 (zine & alloy) 14 48 62 Blectric housewares(aluminum & alloy) 29.0 42 47 (zinc & alloy) 5.6 244 25.3 Lawn & garden equipment {aluminum & alloy) 2.1 335 425 (other nonferrous) = 56 a Motor vehicle parts & accessories (aluminum & alloy) 536.1 691.3 119.9 (zinc & alloy) 5 227 36.7 Power driven hand tools (aluminum & alloy) 36.5 39.9 53.1 (other nonferrous) I 95 126 * Rough & Semifinished 2B mae] Bes Sources : U.S. Department of Commerce & Penton Marketing Information estimates )BEA 10 #3 2119006) eanaeas aur ES.28 FREUN FESO BS wa Ductile Stainless Aluminum Bronze Gray Malleable Zinc | Neon Steel Steel_ Magnesium Brass ton ron Lead_| Die casting . . eo | Continuous . : ; Investment . . . . . Ceramic cope & drag . . . . . Permanent mold . . | Plaster mold 5 . Centrifugal . . . . . Resin shell . . . . . Sand ° . . : 5 5 B64 FRG YS ME a, MY, Ban] ABE Fare Sand Plaster~ Centrifugal Permanent- Die —_ Solid Casting Mold Casting Mold Casting Ceramic | Casting Casting Casting | Mold material Sand _—Plaster*— Sand* Metal* Metal Metal Ceramic | Porosity 6 4 2 1 3 453-4)" 1 ‘Surface 6 1 5 3 4 2(1-2)5 1 Tolerances 6 2 5 3 4 1 1 Strength of solid metal? 6 5 3 2 4 1 1 ‘Thick section 6 1 5 3 4 2 1 ‘Speed of pro: duction for sm all runs‘ 1 4 2 3 5f 3 ‘Speed of pro: duction for lar- | ge runs! 6 5 4 2 3 1 4 | Possibility to | save machining 5 1 4 2 3 1 1 | Cost per piece" 5 6 4 2 3 1 5 ‘Tool cost 1 3 2 4 4 5 3 % Sabb She ato] Gebel ate): 134 2644 ® Copper and aluminum ~based alloys Cold chamber machines, © Hula] say Bata ‘gee 4st de $ For some aluminum based alloys lower than in sand Oppaaae ME AVE He] VewD | *deltawe agave Ageia AateEs Agate dee gee | ree. * 293} PMS ATE a seh asl zl 3. Chol AS) Bea S SHS! He Hol#Agoe F49= FH GEES aA Deel s, Fe), HIG, Belz oes Ua ad. le PEI FIs Le aa ya mM BUS, BAPHE VO, viele HABS} 3 1A] BFK HQ rela Bee] Ha ve slo} gle}, ©] Hol Folal vist gel Fela HF Bae aa Adee ws ou F29] S1FS BPE AS YF seh FAY Gee zat mel olela eel 7h eeebo] Eea oytArieel wee ee - ola E70 AG Med VA, F254, le) whe Agqza AS Copper Cu Mg the Zn Ht (Brass) AR aa Tensile “Stength 3 1 (strongest) 3 2 Impact Strength 3 1 (toughest) 3 2 Elongation 4 1 (most ductile) 3 2 Dimensional Stability 2 1 (most stable) 3 3% Resistance to Cold Flow 2 1 (most resistant) 2 3 Brinell Hardness 3 1 (hardest) 3 2 eelal dal Electrical Conductivity 1 (highest) 2 3 2 Taermal Conductivity 4 (highest) 2 4 3 Melting Point || 2 3 2 1 (lowest) Weight. per cu, in 2 4 1 (lightest) 3 FEa4a Ease, Speed of Casting 2 3 2 1 easiest) Maximum Feasible Size = 8 2 1 (largest) Complexily of Shape 2 3 2 1 (most complex) Dimensional Accuracy 2 3 2 1 (most accurate) Minimum Section Thickness 2 3 2 1 (thinnist) Surface Smoothness 2 3 2 1 (smoothest) we Die Cost-+ 2 3 2 1 Gowest) Production Cost 2 3 2 1 (lowest) Machining Cost 2 3 1 1 Finishing Cost++ 3 2 4 1 (lowest) Cost per Pico § 2 3 2 1 Mowest) Extent of Use 2 4 3 1 (most used) % ASoHdBoe Zee AFH DIO ee. ll 28 88] saMes Solar Faye Bole. + AGRE F28 BY] Wea FEE 2M. +++ polishing, buffing "82%, 2E ATA Ae seh § BE, as, ae), ass. he, sree aah 1S) AS SAS Fre AS SF Ve. Ul es Iueg ese AALS FAY BBs] SITUS Ped WP Sw Qo} ro] AAGSS YBaprjel reo Hubs PADS UF eh Fede $2 She EE MIMS FF 7] AS °] & @ ¥ Ma (Metal Matrix Com- posite) 9] YY cho] AAWo} o}.Bs) BU. £ 8HE old AE BY ARES 1 Bo] 3a 8 Base] FA W27 MMCE area Gola aa] Aes AMEE, Be Male) FH 7101, SHA, SSR, MY B AA BSS CEG] Ao]zjat Yep), of sz & MMC $4] 174 ae Bay Aaee (8) AEA Gol stA AUT + Non 7S} BH BY HSs St FE RH aed FF asl BHU, SA AIH 7lAvres las, 7 SNF] LAPS BS Wes aly SF o) PALS AAT Ach tho} 2G aalell ABE BE PAY 123 SS FENG Fu) FM aAA), 1s Go AAD Ba (ADC), "3 A)@ SR AB BA(ASTM), 2h5 AVAS(SAE), FSH2F AZM(UNS) 9] 78 Seto. Yo] ARO ASS TIS FA ASS] a = AW ahs FAM oe FR H-1BT] we] Helm} oO] Sol $100,000) We HEU. Healsely AMA FBS Aasi7]jujo Vol, 10, No. 3 EB. ol7AA Qo} oe F714] MeO] wgalop Aa TSE [ead Aedes aed FP W* Silicon Car-| XXX [Wop al, RAY, wel bide Saag 8 Wade] Sz vable7k a. Alumina | XXX [Q5, 25, doa, w ago] FL AS AoF et. Boron Car-| XX | SS} yuo] FOU bide BOOCel Bold B8I7F oy. Silica x UALS, BH, vst jo) $21 Beso] cp. Boron Ni- stat aes Bre tride 7k FOU Aah age of aie. Graphite x S880] SOU UALS els. FM SHehMe, PEG, WesAa AAME FSH SL Ae] DAs ojof dey Bao AAS aa Ae, yo] qe Aye ‘The Journal of the Korean Foundrymen’s Society ~189- o} Aor, last Arby, telat GAS Al Feat, FVARS UPAAL THe ae age] da wad Reel $x cho] AA gered Ae Aa Sd, eM abet s dy] Be AGE ASUS Basel. oe Alt FFARSS HPS Hest Ge Wyse Ua) BG 2 BAUB 3. AGLB 4 SlBawA. sel HRSA FAG SARS E 9 Fela VG. ATE aed BAFo) Beale ApS Fads Bas Uses 7a) Me ARS SSS] A)ES) Ah 4, CHO} WHALE! 712 te] AAD ASS DE WM AL aH AAS eA Mel, Whe FE Bi, ofa, EES SHA) BS Hol 1s o, Fab =e Te, ale, Be Mole Te S as FS UGA SE] HE TF FZ OSS BAe, 1A Ley Le BA cho] AAG 7IA ES. cho] AAG SaaS 2a 5 (cet 228) a kA) 7 Type Te [Mn] Si [G [ Mo[ Vv [w | P [7a] re eee H-10 | 29] 43 | 33 | 31 [ 28 | 6 | ~~ | c | ——| 92.47 | Good resistance to softening, heat checking Zl, Cu Ho} 4] 3 | 2 | 5.) 2 | 5 | -- |-—] --| 91.8 | Good heat checking & Cracking resistance /Al, Me H-2 | 5] 4] 2 | 5 | 15] 3 | 125 |-~| -~| 902 | Good thermal shock resistance /Al, Mg H-] 4} 4] oa] 5 | 2 | 1 )--])--] -—] 912 | Good wear resistance, to ughness, excellent hot hardness /Al, Mg H-4 | 4] 4] a | 8 | 3 | -- | 524] --| ——| 7.65] Good nigh temperature Property, heat resistance /Cu H-19| 4] 4) 4 | 425] 4 | 22 | 225) --| 42 | 885 | Good hot, shock, abrasion resistandee /Cu Cromo | 24] .99 | .93 | 8] 11] st | 11 | --] Ni | 82.21 | Good thermal fatigue -N 12 resistance, toughness /Al.Cu gro | 4 | 76 | 24] 27] 20 | 125] -- | 02 | -— | 92.63] Good thermal fatigue 80M resistance /ALCu owar | 4 | a7 | itz] sa] 13} 96 | -- ~~ | 90.45 | Good thermal shock M resistance, toughness ‘Supreme| /iCu (9)a olhAa7es) Wd Vea- ola EO Ag Tungsten based Die Materials ee ee Tyee [Co] May S| [Mo] V[ WY] PY] a] Fe ete u-a | 03{ 03] o4| 325] --| 05 | 90| --| ~- | 86.25 | Good wear resistance & toughness at high temperature /Cu H-2 | 035] --| --| 20] --] --] a | --| -~ | 86.65] High compressive strength & wear resistance /Cu H-25 } 05) 03| 03] 4 | --| 10] 18} --| ~~ | 759 | High red hardness & wear resistance /Cu wn | --| --]| --] --]| --] --] 9 | --| siz High resistance to 103 cua heat checking, good wear resistance /Cu,Al Amviloy| ==} -=| --| --| 4 | --] 90 | ==] Nia] 2 | High resistance to 1150 heat checking, good | wear resistance /Cu,Al Low Carbon Mold Steel Die Materials carereeee se Type CO] Ma] S [Ge [ Mo [ V Te | Fe wa Aste p-o | 3| | 5 | | 3 | —--] --] --] -- [97.35] Hotaing Blocks, Zn castings poa | 2) --| --| --] --| --| --| --| itz] ote | High strength, Coa holding block, Zn castings saz | 2) a | --| --| --| --| --| --| -- | 904 [Pb Tin castings 1020 Marag | 3] a) 2 | --| 495] --| --| ~-| 11.72] 84.73 |2n, al castings ~ing 609 All Molybdenum based Die Materials, a) =. Twe [oy Mal Ss | c [Mo] Vv [Ww ve | Fe Sa /aete tm | --| -- == | 94 --[--[ 15 Good thermal 1 fatigue /Al, Cu Mo | 02) -~ == | o9.48 --| --| ts Good thermal =Ti fatigue /Al, Cu SY FAM SOA GOO, 2B 1A We Bat dol UAH WY] ig Bay vs ayy AMS co] AAG az wes Poh. ae aM fo] AS ashe we] AS Bey cho} AAG NACE AS SHS SHE WFAA Fe Bel dey ead Bae BSE. o] F AAS Aelae DE ae} AF BEE FIA FU a= YO] Shot (10) Sleeve Hoge B19} HVS AS aol vot SAFE WRG, TY Shot Sleeve F394) BGo] Ig ASsa VLEs ays wee FU P40] pelAwE oS Yao] FUE a Sais Gale] leh EE ol SIS we SE ag Qe PSSM Be a7 HS Fa = \RSI7] Ro} GRAZ) BAO) Bae o] AM SSA 12007) AES WHE FE BhFEA 10-89 £19906) BaeZetal =191- Tog Link Statinary Bie hect Tope fk Sytem Acamultor eswerap Pee | nn Mio ynte gues Bie Cle Cynder ARIUSTABLE | aoing Crimer De Cine SEE cg tan Si Bese TATN | Pate Teyecten Chiooe’ gt Ee dost Fuser see (5 eae \ Jey =a : “BPs Mattie N XV oes a Sun and Task Election Distance Pot Formace ‘Autoratee Liston Cylinder Piece 7 Paro aad Meter Accuitor Pure EL Be Ws 1st Gola 7171 Pe js) neta Th. “LY BA 1959 Bol VF) 71FVWIS Olt ALE MeLAApo) Say eked Acurad eee Reta Per, Biscuit Penetration \ [me | | QA “er Pings sn Piston rs eit aeiteoc | \ Bestin Ser remote hee alin ew Schnee Paes ‘nection Cnet Fel 2. Ae BMS 1 Ho] RAW 7a) het, BBo| FA Bebo, Acurad= BASs wo} Fo] YS PES Moss LEM ol SVS 21-344] UBEAHE logo Werle Wale} $ AALS AHR. o] SAI SMe g BS Fea oF FYBAS BSE zlo} dows dave SAWS SVS MP CH o] SAD 49 SAAS NSS Fl7] AA BaD BASU VANES] AF (biscuit penetration) = Sa TSS HaAFEM lssa Ah ea We AE, $89 VE FUSE EE BAS E, RA FY BUA OG, BVA HESS ASS SANE NTI VAS SolT Ad. + A cho] AR AS Wh Ate) S(insets)\S a AA HES US7l Neh AEST BO} o} Bz VHA 4 HE”), of ral Se + 2 WS oO] Bshe IAS AS: ORE Wy) BY Solaire | YOM le FAS] Hel Fixed Holow Feed Toe to Inger Paton Onter Cyr ‘outer Piston TE 3 Acurad $99) ASE (ws SUA} BOS AIG FAS LIT UH PAAR BF ato} $a) Bo] BE BUA] OF AHSe! AAAI, ak 7AeMapeh LAY Met 2~6IA BET.) ayae Aol che) AAG EY Ba Ast aajey] aed HRY FAY Sola A] MEA, Ee o} PAE NSE AP FM BIE Bo Wa AS Bo] BLS AS PHS soley, of Qe #4 Go] ALY WAS PMA} EOE} AEBALSIA}SH £189 Shot sleeve 2] 3719} 491 0] A AA¥ (squenge process) & Sao Dee Tt AEA HAI] AS seo] EM SH, AGS FY cols azo} % ole HAE 2 add BS AoE o) BS Bol 1 ESSE Ap), Ppaoe 1 cho] AZ 7A] v|RU AHS S toh seh, ophaw ies waded - ae 5. ae ABA Yo] Aad Be a LAGS S Ae 4 dEVAIS Be FAcoIAg Bl B10 Sto] AAG 28) "MACHINE MANUFA. | MACHINE MACHINE MANUFACTURER CTURER NAME TYPE CAPACITY ADDRESS & TELEPHONE ‘Alpha Machine, Hot up to 600 tons 480 W. 199th St. Ine, Cold up to 600 tons Cleveland, OH 43135 | 216—267- 9040 ‘American Hot up to 18 tons 5135 North Ravenswood Hydracast, ‘Ave. Chicago, IL. 60640 312—784—2600 Birch Hot | small—150 tons 11160 Dixie Highway Machinery Co. Cola | large—1000 tons Birch Run, MI 48415 517-624-9373 Die Tech Hot up to 16 tons 350 Kinsley Ave. Bldg | Industries, Gola N/A 42 Providence, R102908 Le, 401-273-7250 Ex—Cell-O Hot ‘up to 1000 tons 345 B. 48th St Micromatic Cold up to 3500 tons Holland, MI 49423 (B&T) 616-392-1461 Frech Hot up to 500 tons Suite 3, 1900 E. US 20 US.A | Cold up to 500 tons Michigan City, IN46360 poe esane LY - | eta sra—2ate _| HPM Hot up to 600 tons Mount Gilead, Corp. | Cola up to 3000 tons OH 43238 419-946-0222 | Harvill — Hot up to 700 tons 24201 Orange Ave Machine, Inc Cold up to 1600 tons Perris, CA 92370 714-687—3198 Idea Hot ‘up to 320 tons | 407 B. Elmwood Troy, U.S.A, Inc cold up to 900 tons MI 48084, 313-588 2823 (12)jujo Vol, 10, No. 3 ‘The Journal of the Korean Founidrymen’s Society 193- [MACHINE MANUPA. | MACHINE MACHINE MANUFACTURER CTURER NAME TYPE CAPACITY ADDRESS & TELEPHONE. Lester Hot up to 900 tons 445 Allen Rd. Engineering Cold up to 3000 tons Stow, OH 44224 Company 216-928-2020 National, Hot up to 130 tons 196 Corp. Park 33 ‘Company Cold, up to 65 tons: Plan way, warwick Rhode Island 02886 AOL=T37 ~3005 Prince Hot 2502500 tons Windcrest Drive, Corp. Cold 250-3500 tons Holland, MI 49423, 616-392-5151 SMT Inc, Hot up to 275 tons 418 Benefit St, Cold up to 275 tons Pawtucket, RI 02861 401-722-8889 Tekcast Hot ‘Small 12 Potter Ave. ‘Company New Rochelle, NY 10802 914-576-0222 THT Cold 50~ 300 tons. 6101 Webster Street Company Daton, OH 45414 513-898-2012 Toshiba Hot 80-500 tons 785 Greenleaf Ave., Company Cold 2503500 tons Elk Grove Village, TL 60007, 312-593-1616 UBE, Cold 140-4000 tons (666 5th Ave. New York Industries, N.Y. t0103 Inc 212-765-5865, Bele Rhy} USS AEA wate. Ho] WAG AVS SAY Fe Bron} "eo ALY Et Passe gow o| PopoH ae RAPE MEA Vel, ole Aa Pel 7 APR YE ASH RM MH WG SR ede tes @ zolc, a a zazed@ 1. Lewis, R.L., Chu, Y., Chen, C., Han, M., and Kim, H., State of the Techonlogy in Die Casting, Report No, ERC /NSM~87— 12, 1987. 2, Burba, B. and Kantner, B., A Worldwide Look at Die casting, Die Casting Engineer, pp. 24-26, 1987, 3. State of the Industry Report, Precision Metal, Nov. 1986, (13) 4, SME, Tool & Manufacturing Engineers Handbook, Vol. 2, Forming, SME Publi- cation, Dearbon, MI, 1984. 5, Gurganus, T.K., Metal Matrix Conposites talk Outline, Alcoa Lab, PA, 1986, 6, Metal Progress, Compositions and Proper- ties of Casting Alloys, Metal Prgress, 1985. 7, Street, A, The Diecasting Book, Portcul- lis Press Ltd,, Redhill, Surrey, England, 1977. 8, MacLaren, J.L., The Acurad Story, Kie Casting Engineer, SDCE 1966. 9, Sakamoto, T., Art Content and Its Effect on Casting Quality, SDCE Transaction, 1985, 10. Mulholland, K.A. Vertical Die Casting Machine, SDCE Transaction, 1972.