Casting Examples - A&B Die Casting

Casting Examples - A&B Die Casting

CLICK HERE TO RETURN TO A&B DIE CASTING HOME PAGE Casting Examples Aluminum section 9 9-2 Pistol Frame Rocker Arm Right/Left Hand Bracket Endbel...

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Casting Examples

Aluminum

section

9

9-2

Pistol Frame Rocker Arm Right/Left Hand Bracket Endbell Engine Base Bracket Water Passage Heat Sink Front & Back Chassis B Pillar Trimmer Deck Housing RFU Enclosure Impeller Lower Crankcase Differential Carrier Beta Crankcase Right & Left Scooter Monocoque Frame Rear Wheel Drive Northstar Block Casting Power Condition Module Chassis MMC Brake Drum AWD Clutch Housing RWD Transmission

Magnesium

9-2 9-2 9-2 9-3 9-3 9-3 9-4 9-4 9-4 9-5 9-5 9-5 9-6 9-6 9-6 9-7 9-7 9-7 9-8 9-8 9-8

Zinc Knot Bracket Faucet Handle Connector Kitchen Faucet Hub Fuel Fitting Reverse Valve Casket Casket Arm Display Frame Component Outside Cover Front Plate L-20 Connector Housing Rearview Mirror Mount Steering Wheel Ignition Lock Housing Headlamp Visor Camera Bracket

ZA (Zinc-Aluminum) Tool Housing & Components Transmission Shift Selector Tube

9-14 9-14 9-14 9-14 9-15 9-15 9-15 9-16 9-16 9-16 9-17 9-17 9-17 9-18 9-18 9-18 9-19

9-20 9-20 9-20

9-9

Frame Head Node Fishing Reel Clutch Cover Camera Assembly Hand-Held Computer Housing Gear Case Housing Assembly Lock Housing Fairing Support Bracket Seat Back and Cushion Lift Gate Inner Panel Cross Car Beam for Instrument Panel Oil Tank SAWZALL Gear Case Assembly

9-9 9-9 9-9 9-10 9-10 9-10 9-11 9-11 9-11 9-12 9-12 9-12 9-13 9-13

9

NADCA Product Specification Standards for Die Castings / 2015

9-1

Casting Examples Aluminum Part Name:

Pistol Frame

Application:

0.22 Caliber Pistol

Part Weight: 0.35 lbs. Alloy:

A380

Comments:

Part was previously machined from stock. This is the first aluminum die casting used by Smith & Wesson.

Customer:

Smith & Wesson

Aluminum Part Name:

Rocker Arm

Application:

Honda Civic Engine

Part Weight: 0.48 lbs. Alloy:

383

Comments:

Process improvements and strict attention to detail resulted in cost savings on these high integrity, near porosity-free parts. The parts include a special “wear” insert chip and meet very tight specifications.

Customer:

Honda of America Mfg., Inc.

Aluminum

9-2

Part Name:

Right/Left Hand Bracket

Application:

BRP Skidoo

Part Weight:

0.75 lbs.

Alloy:

Aural-2

Comments:

Part was previously made from low pressure permanent mold with extensive machining. High vacuum die casting created a heat treatable and weldable part for structural application, requiring minimal machining. Overall piece price reduction was on the order of 40%.

Customer:

BRP Skidoo

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Aluminum Part Name:

Endbell

Application:

Air Compressors

Part Weight: 0.85 lbs. Alloy:

380

Comments:

Major tooling and process improvements resulted in scrap reduction, increased cost savings, production and quality. Completed cast units highly competitive in the market against lower entry models produced using stamped steel.

Customer:

Devilbiss Air Power Company

Aluminum Part Name:

Engine Base Bracket

Application:

Honda Accord Engine

Part Weight:

6.2 lbs.

Alloy:

ADC3SF jointly developed with Honda, compatible with SF36, Aural 2

Comments:

Replacing a previously stamped, 16 piece part, the new part is 27 in. long, thin-walled, with screw bosses, eliminating the welding operation and reduced weight by 43.6%.

Customer:

Honda

Aluminum Part Name:

Water Passage

Application:

Honda Civic Engine

Part Weight: 1.4360 lbs. Alloy:

383

Comments:

The Water Pasage hose mating surface is cast to specifications allowing the shipping of the part to the customer without any machining to the snout. This tight tolerance allows a cost savings to the customer. The customer saves the cost of machining for the snout, which is estimated at a 23% cost savings.

Customer:

Honda of America Mfg. Inc.

NADCA Product Specification Standards for Die Castings / 2015

9

9-3

Casting Examples Aluminum Part Name:

Heat Sink Front & Back

Application:

Garmin G-1000 Flat Panel Flight Display

Part Weight: 1.91 lbs. Alloy:

360

Comments:

Parts are assembled to collect & disperse heat from an LCD unit. Converted from machined parts to die castings. Increased production rate & reduced piece part cost. First time use of aluminum heat sink for this type of application. 360 alloy was selected based on it’s corrosion resistance which protects the assembly from oxidation & other corrosion resulting from frequent atmospheric changes experienced by components used in general aviation. Painting or coatings are not required & are ready for assembly upon arrival at customer location.

Customer:

Garmin International

Aluminum Part Name:

Chassis

Application:

Human Transporter

Part Weight: 8.2 lbs. Alloy:

380

Comments:

The casting is produced to net shape and meets strict specifications. True position tolerances on critical dimensions were reduced resulting in reductions in machining and substantial cost savings.

Customer:

Segway

Aluminum Part Name:

B Pillar

Application:

Automotive Structural Support

Part Weight: 9.2 lbs.

9-4

Alloy:

380

Comments:

A new part cast for automobile body framing support application. Yields weight savings benefit over fabricated steel components.

Customer:



NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Aluminum Part Name:

Trimmer Deck Housing

Application:

Walk Behind Trimmer

Part Weight: 9.2 lbs. Alloy:

380

Comments:

As compared to a previous die casting design and tooling design, newly designed tooling allowed for scrap reduction (34%), cycle time reduction (52 sec.) and weight reduction (2 lbs.).

Customer:

Garden Way, Inc.

Aluminum Part Name:

RFU Enclosure

Application:

Microwave Communications

Part Weight: 15.8 lbs. Alloy:

413

Comments:

Formerly produced as an investment casting. Provides heat dissipation and electrical conductivity. Die casting reduced lead time and machining requirements.

Customer:

Harris Corporation, Microwave Communications Division

Aluminum Part Name:

Impeller

Application:

Industrial/Commercial Blower

Part Weight: 10.29 lbs Alloy:

A380

Comments:

Impeller used in industrial and commercial blowers. The application of the die cast part enabled the unit to operate at higher speeds, with less noise, while reducing the amount of secondary machining.

Customer:

Ametek Rotron

9

NADCA Product Specification Standards for Die Castings / 2015

9-5

Casting Examples Aluminum Part Name:

Lower Crankcase

Application:

Motorcycle

Part Weight: 16.31 lbs. Alloy:

LM2 to JVM Specifications

Comments:

Redesign of original T120, 1959 Bonneville high performance version of Triumph’s 650cc twin. Eliminated costly secondary machining operations, additional engine parts and fully utilized the benefits of high pressure die casting process.

Customer:

Triumph Motorcycles

Aluminum Part Name:

Differential Carrier

Application:

Independent Rear Suspension

Part Weight: 16.5 lbs. Alloy:

ADC-12 -T6 Heat Treatment

Comments:

Past generation was an iron casting. First high volume squeeze casting used in an independent rear suspension axel carrier. Squeeze casting decreased weight by 22 pounds over cast iron process.

Customer:

Visteon Corporation

Aluminum Part Name:

Beta Crankcase Right & Left

Application:

Motorcycle

Part Weight: 16.8 lbs.

9-6

Alloy:

383

Comments:

These net-shape, complex castings were converted from the permanent mold process to meet stringent specifications of improved quality, pressure tightness, cosmetic appearance, higher volume and cost reductions.

Customer:

Harley-Davidson

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Aluminum Part Name:

Scooter Monocoque Frame

Application:

Honda Scooter Super Sport

Part Weight: 23.4 lbs. Alloy:

JIS ADC12; 383 equivalent

Comments:

Previously fabricated from steel sheet stamping and pipes. Die casting provided weight savings and cost reduction.

Customer:

Honda R&D Co., Ltd.

Aluminum Part Name:

Rear Wheel Drive Northstar Block Casting

Application:

Rear Wheel Drive Northstar Engine

Part Weight: 79.83 lbs. Alloy:

A380

Comments:



Customer:

GM Powertrain

Aluminum Part Name:

Power Conditioning Module Chassis

Application:

Computer/Electronics

Part Weight:

2.3 lbs.

Alloy:

380

Comments:

Originally machined from a roughly shaped ingot, this chassis gained significant cost savings after being converted to an aluminum die casting.

Customer:

Novatel Wireless Technologies, LTD

9

NADCA Product Specification Standards for Die Castings / 2015

9-7

Casting Examples Aluminum Part Name:

Aluminum MMC Brake Drum

Application:

Commercial, Military, and Special Vehicles

Part Weight:

38.5 lbs.

Alloy:

A356.2

Comments:

Originally produced in cast iron. A unique horizontal squeeze cast process allowed a selectively placed ceramic preform to be infiltrated, creating a selectively reinforced, Metal Matrix Composite (MMC) aluminum brake drum. The new brake drum weights at least 45% less.

Customer:

Century 3+ Inc.

Aluminum Part Name:

Automotive AWD Clutch Housing

Application:

Automotive

Part Weight:

2.4 lbs.

Alloy:

ADC12-T5

Comments:

Originally produced as a multi-step forged steel housing, but this part was successfully convert this part to an aluminum squeeze casting. The new squeeze cast design incorporated 33 spline teeth with 0.1 degree draft. A significant mass reduction was obtained resulting in better fuel efficiency and reduced inertia for improved all wheel drive engagement response time.

Customer:

Borg Warner TTS, PTC

Aluminum

9-8

Part Name:

RWD Transmission

Application:

Automobile Industry

Part Weight:

37.4 lbs.

Alloy:

A380

Comments:

Utilizes a unique process, involving 2 cast-in steel tubes, which have to be inserted in the ejector die and maintain location.

Customer:

Chrysler

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Magnesium Part Name:

Frame

Application:

Novatel Expedite Modem

Part Weight: 0.01 lbs. Alloy:

AZ91D

Comments:

Converted from a plastic part. The magnesium casting eliminated a plastic part sandwiched between two metal plates and held together with self tapping screws, resulting in cost savings to the customer.

Customer:

Novatel Wireless Technologies, LTD

Magnesium Part Name:

Head Node

Application:

Mountain Bike

Part Weight: 0.22 lbs. Alloy:

AZ91D

Comments:

Originally designed as two aluminum investment cast parts, this unique die cast mag design and application yields a 30% weight savings, part and assembly cost savings, better consistency in impact and fatigue and better performance.

Customer:

Cannondale

Magnesium Part Name:

Fishing Reel

Application:

Ardent XS Fishing Reel

Part Weight: 31.3 grams Alloy:

AZ91D

Comments:

Converted from plastic & die cast aluminum components. Complex geometry & varying wall thickness. Tooling uses 3 slides to form entire exterior of part. Tight tolerance machining of bores and surfaces for mating components. 100% made in USA (Components & Assembly).

Customer:

Marsh Technologies, Inc.

NADCA Product Specification Standards for Die Castings / 2015

9

9-9

Casting Examples Magnesium Part Name:

Clutch Cover

Application:

All Terrain Vehicle Clutch

Part Weight: 0.44 lbs. Alloy:

AZ91D

Comments:

A conversion from aluminum die casting to magnesium die casting resulted in a weight reduction of 45% and a significant cost reduction by eliminating machining.

Customer:

Polaris Industries, ATV Div.

Magnesium Part Name:

Camera Assembly

Application:

Digital Camera

Part Weight: 0.48 lbs. Alloy:

AZ91D

Comments:

Originally designed as aluminum investment cast parts, the design complexity and required precision mandated a transition to magnesium die cast parts.

Customer:

Eastman Kodak

Magnesium Part Name:

Hand-Held Computer Housing

Application:

Hand-Held Computer

Part Weight: Over 0.5 lbs.

9-10

Alloy:

AZ91D

Comments:



Customer:

Telxon Corporation

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Magnesium Part Name:

Gear Case Housing Assembly

Application:

Automatic Power Pruner

Part Weight: 0.64 lbs. Alloy:

AZ91D

Comments:

Magnesium was chosen for it’s strength and low weight for this application over plastic and aluminum. Bearing diameter tolerances of 0.001” are required and eliminate machining and masking cost.

Customer:

Echo

Magnesium Part Name:

Lock Housing

Application:

SUV Tilt Steering Column

Part Weight: 2.02 lbs. Alloy:

AM60B

Comments:

This die casting controls the tilt/telescoping features in the steering column and incorporates the ignition switch, shift lever and brake-shift interlock into one casting. In addition to tight dimensional control, the higher elongation in AM60B alloy provides good crash energy management.

Customer:

Visteon/Ford

Magnesium Part Name:

Fairing Support Bracket

Application:

Buell 1125R Superbike

Part Weight: 2.71 lbs. Alloy:

AZ91D

Comments:

This bracket provides support for the motorcycle’s instrument cluster, windshield/cowling, direction signals and rearview mirror with increase copacity and a cost savings of aproximatly 26%.

Customer:

Buell Motercycle Co.

NADCA Product Specification Standards for Die Castings / 2015

9

9-11

Casting Examples Magnesium Part Name:

Seat Back and Cushion

Application:

Luxury Car Seat Back and Cushion

Part Weight: — Alloy:

AM60B

Comments:



Customer:



Magnesium Part Name:

Vehicle Lift Gate Inner Panel

Application:

Automotive

Part Weight: 18 lbs. Alloy:

AM60

Comments:

Replacing a stamped steel assembly, this large die cast magnesium lift gate reduced weight, added design flexibility and reduced assembly time through the integration of various components. The die cast lift gate is 54 x 52 inches.

Customer:

Ford Motor Co.

Magnesium Part Name:

Cross Car Beam for Instrument Panel

Application:

General Motors Medium Duty Trucks

Part Weight: 21.5 lbs.

9-12

Alloy:

AM60B

Comments:

An example of maximizing the die casting process, machine and die to obtain substantial cost savings. The improvements resulted in weight savings & cost reductions through decreased material, downtime, and elimination of machining/ repair.

Customer:

General Motors Truck

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Magnesium Part Name:

Oil Tank

Application:

Snowmobile

Part Weight: 2.03 lbs. Alloy:

AZ91D

Comments:

This magnesium oil tank replaces one that was a stamped aluminum and brazed assembly. The case is comprised of 3 separate magnesium die castings. It is lighter and more tunable than the aluminum it replaces.

Customer:

Arctic Cat Inc.

Magnesium Part Name:

SAWZALL Gear Case Assembly

Application:

Power Tool

Part Weight: .293 lbs. Alloy:

AZ91D

Comments:

Met customer requirements of eliminating machining and reducing cost of similar aluminum castings. Magnesium die casting holds dimensional tolerances that eliminate the need to machine.

Customer:

Milwaukee Electric Tool Co.

9

NADCA Product Specification Standards for Die Castings / 2015

9-13

Casting Examples Zinc Part Name:

Knot

Application:

Marketing

Part Weight: 5.5 Grams Alloy:

ZP5

Comments:

This item’s shape has never been industrially manufactured and displays ingenious part and tooling design.

Customer:

Nyrstar

Zinc Part Name:

Bracket

Application:

Electronics Enclosure

Part Weight: 15.42 Grams Alloy:

Zamak No. 3

Comments:

Converted from a machined aluminum alloy resulting in cost savings. The part is cast to net-shape thereby totally eliminating any machining.

Customer:



Zinc Part Name:

Faucet Handle

Application:

Two Handle Lavatory Faucet

Part Weight: 119 Grams

9-14

Alloy:

Zamak No. 3

Comments:

Major cost savings were achieved from tooling changes, which eliminated trimming, reduced polishing the parting line and machining operations.

Customer:

Delta Faucet Company

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Zinc Part Name:

Connector

Application:

“TERA” Connector

Part Weight: 0.4 oz. Alloy:

Zamak No. 3

Comments:

Die casting offered superior EMI shielding and mechanical integrity at a favorable cost.

Customer:

Siemon Company

Zinc Part Name:

Kitchen Faucet Hub

Application:

Pull-Out Faucet

Part Weight: — Alloy:

Zamak No. 3

Comments:



Customer:

Delta Faucet Company

Zinc Part Name:

Fuel Fitting

Application:

Dragon Fly™ Cook Stove

Part Weight: 0.5 oz. Alloy:

Zamak No. 3

Comments:

Originally designed as an assembly of three screwmachined components. Converting the component to die cast Zamak 3 provided a cost reduction and allowed for the streamlining.

Customer:

Mountain Safety Research

9

NADCA Product Specification Standards for Die Castings / 2015

9-15

Casting Examples Zinc Part Name:

Reverse Valve Casting

Application:

Snap-On Tools

Part Weight: 1.06 oz. Alloy:

Zamak No. 5

Comments:

Exceedingly complex, high tolerance die casting produced in high volumes & requiring minimum machining. Zinc die casting selected over powder metallurgy, machining & metal injection molding because of lower production costs. 50 mils to 230 mils casting thickness & a stepped hole (to a final ID of 0.3000”) extending the length of the cylinder with minimum draft.

Customer:

Vic Royal

Zinc Part Name:

Casket Arm

Application:

Casket

Part Weight: 3.5 oz. Alloy:

Zamak No. 3

Comments:

This precisely cored zinc die casting provides the right amount of friction with the hinge to allow the lift bar to remain in the position it was last set. Was a steel stamping.

Customer:

Vic Royal

Zinc Part Name:

Display Frame Component

Application:

Store Display Unit

Part Weight: 26.16 oz.

9-16

Alloy:

Zamak No. 3

Comments:

Conversion from a steel weldment to a die casting resulted in substantial cost savings. The casting is used as the frame for a track running shoe display rack.

Customer:

CDC Marketing

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Zinc Part Name:

Outside Cover

Application:

Power Lever Door Lock

Part Weight: 3.0 lbs. Alloy:

Zamak No. 3

Comments:

Converted from a permanent mold casting, these die cast parts offer thinner walls, less prep for plating due to the extraordinary surface finish and cost savings (39%).

Customer:

Mas-Hamilton Group

Zinc Part Name:

Front Plate L-20

Application:

Telecommunications Extension Shelf

Part Weight: 3.53 oz. Alloy:

Za4Cu1

Comments:

New part for mounting optical and electrical cartridges. Challenge of fill very thin walls and narrow (0.2 mm) flatness tolerance. Success related to vacuum technology, die thermal conditioning and precision and sprue runner design.

Customer:

ALCATEL ITALIA S.p.A.

Zinc Part Name:

Connector Housing

Application:

Fiber Optic Transceiver

Part Weight: 0.19 oz. Alloy:

Zamak No. 2

Comments:

Previously produced from multiple machined cast metal or sheet metal fabricated parts, which lacked precision for speedy assembly of components. Cost savings in material, production methods and labor were achieved with the conversion to die casting.

Customer:

Agilent Technologies

NADCA Product Specification Standards for Die Castings / 2015

9

9-17

Casting Examples Zinc Part Name:

Rearview Mirror Mount

Application:

Windshild-to-mirror head transition housing

Part Weight:

4.1 oz.

Alloy:

Zamak No. 5

Comments:

The part was designed around the mirror mount’s humidity sensor for the smallest possible footprint.

Customer:

Gentex Corporation

Zinc Part Name:

Steering Wheel Ignition and Lock Housing

Application:

Automotive

Part Weight:

13.9 oz

Alloy:

Zamak #5

Comments:

The ignition and lock housing is a safety-critical component of the automotive steering column. It keeps the steering wheel locked until the car is ready to start and drive.

Customer:

Valeo Sisitemas Electronics, SA de CV

Zinc

9-18

Part Name:

Headlamp Visor

Application:

Harley-Davidson Motorcycle

Part Weight:

2.78 lbs.

Alloy

ZA8

Comments:

Combined two parts into one to reduce cost and part numbers. As the center point of the integrated motorcycle handlebar assembly it needs to be functional and aesthetic. Carefully controlled process produces a surface finish conducive for a highly cosmetic chrome plate finish.

Customer:

Harley-Davidson

NADCA Product Specification Standards for Die Castings / 2015

Casting Examples Zinc Part Name:

Bracket, Camera, ASIC

Application:

Infrared Interactive Whiteboard

Part Weight:

0.065 oz.

Alloy

Zamak #3

Comments:

This zinc die casting replaces an ABS plastic part. It improves the product durability and performance. The casting is used to hold an infrared camera ridigly in place on an interactive whiteboard. This whiteboard connects to a computer and employs infrared light to locate all interactions with the whiteboard.

Customer

SMART Technologies

9

NADCA Product Specification Standards for Die Castings / 2015

9-19

Casting Examples ZA (Zinc-Aluminum) Part Name:

Tool Housing & Components

Application:

Air-Powered Hand Tool

Part Weight: — Alloy:

ZA-8 and ZA-27

Comments:

The components for this air ratchet tool consist of two die cast ZA-27 split halves incorporating as-cast “grip” surface embossing, logos and identification and a one-piece ZA-8 air manifold that does not require machining. ZA alloys allowed wall thicknesses of 0.060 inch for the handles and enhanced sound suppression for quieter operation. Previously an assembly of a machined steel head and a cast aluminum handle housing that required extensive machining was used.

Customer:

Snap-On

ZA (Zinc-Aluminum) Part Name:

Transmission Shift Selector Tube Unit

Application:

Passenger Car & Light Truck

Part Weight: 1.1 lb.

9-20

Alloy:

ZA-8

Comments:

This single die casting replaced a four piece assembly and resulted in an estimated 50% cost savings.

Customer:



NADCA Product Specification Standards for Die Castings / 2015