Tooling for Die Casting SECTION

Section Contents
1 Introduction
2 Types of Die Casting Dies
NADCA No. Format Page
2-2
2-3
2
2.1 Prototype Dies 2-4
2.2 Production Dies 2-5 2
2.3 Rapid Tooling Dies 2-5
2.4 Unit Dies 2-6
2.5 Trim Dies 2-6
3 Casting Features and Die Considerations 2-6
3.1 Core Slide Requirements 2-7
3.2 Parting Line: Cover & Ejector Die Halves 2-8
3.3 Ejector Pins 2-9
3.4 Cast-in Inserts 2-9
4 Die Materials 2-10
4.1 Die and Cavity Materials 2-10
4.2 Die Cavity Insert Materials 2-10
4.3 Die Steel Heat Treatment 2-11
5 Controlling Die Performance 2-11
5.1 Porosity Control: Gating, Venting, Vacuum 2-11
5.2 Thermal Balancing 2-12
5.3 Oil Heating Lines 2-12
5.4 Alternate Surface Textures 2-12
5.5 Extended Die Life 2-12
6 Secondary Machining Preplanning 2-14
7 Gaging Considerations 2-14
8 Inherited Tooling 2-15
9 Engineering Consultation 2-15
10 Database Guidelines 2-16
11 New Die/Inherited Die Specifications 2-16
12 Die Life 2-16
13 Checklist for Die Casting Die Specifications T-2-1-06 Checklist 2-17
14 Guidelines to Increase Die Life T-2-2-06 Guideline 2-19

NADCA Product Specification Standards for Die Castings / 2006 2-1

 Tooling for Die Casting

A-PARTING LINE
Surface where two die halves 1 Introduction
come together.
B-LEADER/GUIDE The die casting die or mold is a closed vessel into which molten metal is injected under high
PIN & BUSHING
Guides the two die halves pressure and temperature, then rapidly cooled until the solidified part is sufficiently rigid to
together and maintains die permit ejection from the mold.
alignment.
For longevity of operation in this environment the die casting die must be built from high-quality
C-DIE CAVITY tool steel, heat-treated to the required hardness and structure, with dimensions of the die and cavity
Die recess in which casting is
formed. machined to exacting specifications. The two die halves run in a die casting machine that is operated
at the required temperatures and pressures to produce a quality part to net-shape or near-net-shape
D-STATIONARY &
MOVING CAVITY INSERT customer specifications.
Premium grade tool steel The customers product design requirements directly affect the size, type, features, and cost
containing the cavity details.
of the required tooling. The items involved in the tooling decision include the number of cavi-
E-RUNNER & GATES ties, number of core or slide requirements, weight of the die, machining, finish requirements,
Precisely designed passage
thru which metal flows from i.e. painting, polishing, plating, to name just a few. A convenient checklist of die construction
sprue hole or cold chamber considerations, intended for use in discussion with your custom die caster, appears at the end of
into die cavity.
this section.
F-COLD CHAMBER
Passage thru which metal
enters runners and gates.
F1-SPRUE HOLE B LEADER/GUIDE PIN BUSHING
B LEADER/GUIDE PIN
& SPRUE PIN A PARTING LINE
Forms passage thru which COOLING LINE P CLAMPING SLOTS
metal enters runners & gates
in a hot chamber die.
G-CORE C DIE CAVITY L RAIL

Usually a round tapered pin

used to cast various hole
details. D STATIONARY &
MOVING CAVITY
INSERTS
H-STATIONARY/COVER
MOLDBASE
Stationary holder that GUIDED EJECTION
contains and supports the E RUNNER O ASSEMBLY
& GATE
cover inserts. STOP
PIN
I-RETURN PIN F COLD
CHAMBER BUSHING
Large ejector pin that resets
ejection system.
J-EJECTOR PIN RETAINER AND
M EJECTOR PLATE
Pin which pushes casting from
die cavity. SUPPORT
N POST/PILLAR
K-MOVING/EJECTOR
MOLDBASE
Movable holder that contains G CORE
and supports the ejector
inserts.
L-RAILS
Supports the ejector side
moldbase and contains STATIONARY/COVER
clamp slots. H MOLDBASE

M-RETAINER AND I RETURN PIN K MOVING/EJECTOR

MOLDBASE
EJECTOR PLATE J EJECTOR PIN L RAIL

Contains and pushes the

ejector pins. COLD CHAMBER DIE
N-SUPPORT POST/PILLAR
Additional support members RUNNER
to resist die deflection. E & GATE

O-GUIDED EJECTION ASSEMBLY

(STOP, PIN & BUSHING) F1 SPRUE
Fig. 2-1 Shown above is a multiple-cavity cold HOLE
&
Supports and guides the chamber die casting die. With this process the metal SPRUE
ejection system. PIN
enters the die runners, gates and cavity through the
P-CLAMPING SLOTS cold chamber. The Sprue replaces the cold chamber
Opening for die clamps to in the hot chamber process which is used for zinc
mount die halves to machine
platens. and smaller magnesium components.
HOT CHAMBER DIE

2-2 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

Explanation of the most important terms related to die design are given below. A complete
glossary of die casting terms appears at the end of this volume.
The discussion in this section provides a guide to aid the die casting specifier in understanding
the requirements of the die caster that will be necessary to produce the optimum die casting, by
the most economical production methods.
The various alloys available for die casting, from aluminum to zinc, require unique and special
features in the die that produces them. Because of these differences, the descriptions and param-
eters described in this text are generic. Where possible, options are listed but should be used only
2
as a general guide, with the final decisions discussed between the customer and the die caster.

2 Types of Die Casting Dies

There are various types of die casting dies and each serves a critical need for the customer.
The choice of which type of die casting die the customer requires is usually determined by the
following:
Size of the part to be cast
Volume of parts required
Requirements for family sets of parts
Desirability of core slides
Requirements for cast-in inserts.

Fig. 2-2 A unit die casting die, like the one above, allows use of replaceable cavities in standardized
main die frames for lower die costs.

NADCA Product Specification Standards for Die Castings / 2006 2-3

 Tooling for Die Casting

Fig. 2-3 This single cavity die uses the moveable die components (slides) to produce complex features in
the part shown.

2.1 Prototype Dies

Prototype dies are usually requested by the customer to produce a small number of castings under
production conditions. They enable thorough product testing and market exposure before commit-
ting to full production dies. For eventual high-volume programs more than one prototype die may be
produced.
Only production from an actual die casting die can yield a part with precise die cast characteris-
tics. However, there is a range of prototyping strategies that can be employed to approximate a die
cast part for eventual production die casting. Among them: gravity casting, including the plaster
mold process; machining from previously die cast parts or from wrought and sheet stock; and rapid
prototyping techniques such as stereolithography (See the NADCA design manual, Product Design
for Die Casting.)

Die Caster
Owned
Customer Owned

Unit Holder + Cavity Block or Replaceable + Cavity

Cavity Unit` Insert
Fig. 2-4 Components of a unit die illustrate each part of the assembly and the die construction option of a
cavity block or a holder block with cavity insert.

2-4 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

Single-Cavity Die Multiple-Cavity Die

Family Die

2.2 Production Dies

These are the most common types of tools produced. They range from a single-cavity die, with no
slides, to a mulitple-cavity die with any number of slides. The cavities are made from high-quality
tool steel, retained in a quality holder block.
Production dies are built to critical dimensions, coring the maximum amount of stock from
the casting, and allowing the agreed-upon amount of machining. A unit die is a special type of
production die.

2.3 Rapid Tooling Dies

Rapid tooling is a term that refers to dies and inserts produced by methods shorter in lead-time
than the conventional method of rough machining, heat treating, and finish machining. Rapid
tooling methods include processes such as LENS (Laser Engineered Net Shaping), EBM (Electron
Beam Melting), RSP (Rapid Solidification Process), SLS (Selective Laser Sintering), DMD (Direct
Metal Deposition), and high speed machining of pre-hardened tool steel. Tools produced by these
methods may be utilized as prototype or production dies. Production volume requirements may
dictate which rapid tooling methods are most viable.

NADCA Product Specification Standards for Die Castings / 2006 2-5

 Tooling for Die Casting

2.4 Unit Dies

A unit die is a lower cost production tool that has a standardized main die frame and replaceable
cavity units. These replaceable units are designed to be removed from the main die frame without
removing the standard frame from the die casting machine.
The most common commercial types of unit dies are single and double unit holders. These types
of dies are generally used for smaller parts, or a family of parts, with no slides or a minimum
number of slides. Unit dies limit the use of core slides because of the configuration needed for
interchangeable unit inserts and the limited space available.

Fig. 2-5 Photo on left shows untrimmed zinc die casting as it comes from the die. At right, the same cast-
ing after trimming.

2.5 Trim Dies

The trim die is a tool that trims the runner, overflows, and flash from the casting. The trim dies
are single or multiple cavity tools, made in the same configuration as the die casting die.
Depending on the shape of the casting, the trim die may be a simple open-and-close trim die or
it may include as many slides as the die casting tool. In some cases multiple station trim dies will
be used for successive trimming operations.
Trim dies require as much attention to detail in design as the die casting tools and the use of
quality materials should be specified to extend their productive life.

3 Casting Features and Die Considerations

The features that are required of a cast part determine the complexity of the die. The simpler the
part, the lower the cost of the die casting tool.
The customer should look at the casting in terms of total manufacturing cost. The die caster
will aid the customer in examining not only the part designs castability, but also all of the
secondary operations that may be required.
Castability and die cost will be determined by answers to the following: Are the wall thicknesses
as well as the ribs constant, or do they vary greatly? If bosses exist, do they vary widely in diame-
ter? Will any thin channels on the design create thin standing slivers of steel on the die? Is the part
number and other engraving recessed into, rather than raised out of, the casting, making the die
more difficult to machine? Are the cored holes that may be called for extremely small in diameter
and thus difficult to cast? Is the part designed with sharp corners, promoting stress cracks or with
generous radii? See the figure below and fillet information on page 6-4.
For the proper design of production tooling, pressure tightness, secondary machining and
surface finishing specifications must be understood in detail. Areas of the casting subject to
machining must be fully discussed at the outset, so that the die can be designed to reduce to an
absolute minimum the presence of porosity in those areas. Cosmetic surface requirements for the
casting will require specific steps in finishing the cavities of the die.

2-6 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

Fig. 2-6 Most cracking can be eliminated with larger radii.

These are among the types of questions that the customer should be prepared to discuss with
the die caster while reviewing the supplementary checklist at the end of this section.
The Engineering and Design sections provide detailed treatment of the tolerancing implications
of various casting design features, as well as guidelines which apply under differing casting
conditions.

3.1 Core Slide Requirements

Fixed cores and core slides (or pulls) can be designed in the die to cast selected features in place,
eliminating the need for most or all secondary machining of the cast part.
Core slides, similar to collet or cam movements, can be activated by various sources of motion.
Two of the most common are angle pins and hydraulic cylinders.
The angle pin is a mechanical source of motion that is activated by the die opening and closing.
Its advantages are that it does not require hydraulics or limit switches, and is generally more

Fig. 2-7 This ejector die half shows the two moveable cone-shaped core slides, A, at left which
form the interior of the die castings in this two-cavity die. Opposite slides are at the right.
NADCA Product Specification Standards for Die Castings / 2006 2-7
 Tooling for Die Casting

economical to manufacture. Its limitations are that it can be used only for short slide travel and
there is no control over the cycle of the slide pull. It is not recommended for use on top slides.
The hydraulic method of slide motion permits: a choice of cycles, the placement of slides on the
top of the die, and avoids interference when removing the casting from the die (as is the case with
the angle pin).
Among the other methods of motion are rack and pinion, ejector lifter, and cam bars. The
choice of motion depends on factors such as production volume, size of die, length of travel of
slide, size of area being cored out and the configuration of the part. The die caster should be
relied upon for the optimum recommendations on core slides, also called moving die components
or moving die parts.

3.2 Parting Line: Cover and Ejector Die Halves

The parting line is that perimeter on the casting which is the separation point of the two halves of
the die casting die. This line affects which half will be the cover die half and which will be the
ejector half.
This line also influences any tolerances that must be held in this area of the casting. Toleranc-
ing standards specific to part characteristics at the parting line are presented in Engineering and
Design, Section 4A.

Parting
Parting
Line A
Line "A"

Parting
Parting
Line "B"
Line B

Fig. 2-8 Step parting line A, originally placed on this casting drawing would not
have produced the best production results. The location of the parting line B in the
bottom drawing will allow better casting fill and cleaner casting trim, plus provide
longer die life and a less costly die to build.

It is not obvious where the parting line on a casting drawing should be placed. Where the
parting line is indicated by the part designer, it is necessary for the die caster to confirm the
designers determination. Agreement on the optimum parting line location is essential for the
casting to be produced to the desired specifications.
In the case of a part that must have a cosmetic surface, the cover half will generally be used to
produce the cosmetic surface. This permits the ejector half to contain the ejector pins, inserts and
any engraving.
If there is no cosmetic surface requirement, the casting can be oriented to suit the most favor-
able casting conditions. On cosmetic parts, the customer must discuss with the die caster where
the gate, overflows and vents will be, to be certain that there is no interference or blemish on the
important cosmetic surfaces.

2-8 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

%JECTOR$IE 2

$IE#ASTING

Fig. 2-9 Ejector pins, shown in black, are recessed as the metal fills the die cavity (above left); then actuate
sequentially to release the casting from the die (above, right).

Where there are cosmetic requirements, since normal, incremental die erosion is inherent in
the die casting production process, the customer will want to discuss special die maintenance
procedures to extend the ability of the die to produce parts with the required high-quality surface
finish. Secondary operations to the surface of the part, such as polishing or buffing, should also
be discussed to maintain cast part specifications.

3.3 Ejector Pins

Ejector pins are used to push the casting out of the die after the metal shot has been made and
casting solidified. The location and size of the ejector pins are dependent on the configuration,
size, and other requirements of the casting.
The die caster will always attempt to locate ejector pins in a nonfunctional area of the casting,
such as in an overflow, on a boss, in the bottom of a deep pocket, or the bottom of a rib. His
recommendations are important as to the size, location and number of ejector pins required for
successful part production.
Each ejector pin must be sized to suit the casting configuration in the selected area and will
leave a slight impression on the cast surface. For this reason, they are not placed against the
cosmetic surface side of the part.
Product standards related to ejector pin locations are discussed in Engineering and Design,
Section 6.

3.4 Cast-in Inserts

In some castings, there may be a need for a bearing surface, internal thread, or some other unique
feature that could be accommodated by an insert molded into the casting. This requirement can
often be met by the die caster within the normal operation of the casting process.
This insert molding offers the advantage of firmly setting an insert into the casting so that it
can be machined, drilled and tapped. This advantage, however, rarely offsets the added costs of
the insert casting operation.
The added costs result from reduced machine cycle time, due to loading the insert into the die
and the heating procedure required to heat the inserts before they are placed into the die half.
This preheating is required to avoid putting moisture into the die, allowing metal to chill around
the insert and causing the insert to loosen.

NADCA Product Specification Standards for Die Castings / 2006 2-9

 Tooling for Die Casting

4 Die Materials

The grade of tooling materials to be used in the construction of a die casting die should be
specified as high quality, at a minimum, and preferable premium quality. These requirements are
based on the extremely high temperatures and pressures used in die casting production.
Tooling grade requirements will vary depending on the tooling component, the alloy being
die cast, the critical character of the cast part design and the long-term production quantities
desired. Every aspect of the proposed products design and production specifications must be
discussed with the die caster before tooling material can be selected. The following are typical
tooling lowest requirements:

4.1 Die and Cavity Materials

Die Casting Dies for Zinc Alloys: P-20, H-11, H13, Premium Grade H13 (Per NADCA No. 229)
or Superior Grade H13 (Per NADCA No. 229).
The zinc alloys, which cast at the lowest temperature in the nonferrous family, cause the least
wear on their tooling and thus permit the use of non-premium die material, such as P-20, in cases
where part designs are relatively simple. Purchasers are cautioned, however, to be aware of the
unwise investment in non-premium grade tooling for zinc parts if there is any possibility that
production quantities may reach higher levels than originally anticipated. At higher production
levels, such tooling may expire and the cost of replacement dies will far outweigh an original
investment in premium material.
Die Castings Dies for Aluminum, Magnesium & ZA Alloys
(Noncritical part designs, low volume): H-10, H-11, H13.
Aluminum, magnesium and ZA die casting dies require high quality tool steel, as above. If part
designs have very critical features or if high production runs are being contemplated, however,
premium grade tooling will always be the wisest investment.
Die Casting Dies for Aluminum, Magnesium, ZA-12 & ZA-27 Alloys
(Critical part designs, higher volume): Premium Grade H13 (Per NADCA No. 229)
or Superior Grade H13 (Per NADCA No. 229).
For Al, Mg, ZA-12, and ZA-27 die cast parts, H13 Premium or Superior Grade tool steel is recom-
mended whenever part design features are intricate and specifications tight, and when production
volumes will be high. In such cases, non-premium grade tooling will nearly always result in costly
premature die failure.
Die Casting Dies for Brass Alloys: H13
Since copper alloy die castings are cast at the highest temperatures of the nonferrous alloys,
only H13 high grade tool steel is recommended for brass die casting dies.
Metal certifications for the material grades listed, provided by quality tooling material suppliers,
will be made available for inspection by the die caster. The H13 Premium or Superior Grade
should meet the NADCA No. 229 tool steel standard (Recommended Procedures for H13 Tool
Steel).

4.2 Die Cavity Insert Materials

The materials recommended for use as tool steel for die cavity inserts parallel the recommenda-
tions for die cavities, above, with some additions.
In addition to H13 Premium or Superior Grade, the maraging steels are used for die inserts
needing higher hardness to improve their resistance to the heat checking (thermal fatigue
cracking) or crazing of the inserts surface caused by thermal cycling of the die from the high
temperature molten alloy and die spray/die cooling. The fine cracks that may result can produce
corresponding veins on castings.
In high wear (erosion/washout) and temperature areas, especially if internal cooling and/or
die spray is difficult, small cores and inserts in aluminum die casting dies can eventually break or
wash away due to the velocity of the aluminum entering the cavity. Tungsten- and molybdenum-

2-10 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

based alloys are occasionally used successfully in these areas to resist these conditions. Although
these materials show superior physical properties compared to conventional steels at high
working temperatures, care must be used in machining them. Also, their increased cost must be
considered in the overall cost of the die and number of shots required (life of the die).

4.3 Die Steel Heat Treatment

The quality of the heat treatment of the die steel is a very critical step in the tool building process. 2
The use of high quality rapid quenching heat treatment procedures is essential to normal die life.
Care must be exercised in the heat treatment procedure to balance the issues of distortion with
metallurgial properties that result from rapid quenching. The recommendations of the die caster
should be respected.
Just as tool steel source certifications are made available by the die caster, so are the heat treat
certifications from the selected heat treatment sources. This documentation will certify that the
heat treat was properly carried out to achieve the correct hardness and microstructure.
Tool steel heat treatment should be expected to follow NADCA No. 229 heat treatment guide-
lines (Recommended Procedures for H13 Tool Steel) and the recommendations of the tool steel
manufacturer.

5 Controlling Die Performance

5.1 Porosity Control: Gating, Venting, Vacuum

Although die castings can be expected to exhibit high strength and integrity, some product require-
ments can call for additional steps in the part design, die design and on-line production stages.
Designers seeking to avoid porosity concerns will be alert to such techniques as eliminating
thick wall sections in their designs. (See Product Design for Die Casting for general guidelines).
For specific designs, the engineer should always consult with an experienced die caster before
design parameters are locked in.
Given the final part design, the die caster will follow specified die design guidelines, incorporat-
ing die gating, overflow and venting configurations to evacuate air properly from the die cavity
and reduce porosity to an acceptable level. Where pressure tightness is not a casting specification,
the process can be designed so that residual porosity enters only non-functional, internal areas of

Conventional
Vent Vacuum
Valve

Fig. 2-10 Conventional venting in a die casting die, shown at left, vents air to the atmosphere.
With a vacuum-equipped die, metal is pulled into a closed system, with air drawn by the vacuum
mechanism. A significant reduction in air entrapped in the casting results in lower porosity.

NADCA Product Specification Standards for Die Castings / 2006 2-11

 Tooling for Die Casting

the casting. Porosity is acceptable in non-critical areas.

While not a substitute for sound product and die design, a vacuum system can also be used
to enhance die fill, reduce gas porosity, and improve mechanical properties. A vacuum system is
designed to evacuate ambient air from within the die cavity during casting and create a negative
pressure or a vacuum. The die must be specially built to accept a vacuum system, so discussions of
acceptable porosity levels should be held well in advance of die design.

5.2 Thermal Balancing

To achieve maximum product quality, the dies are required to run at a precise, specified tem-
perature. This temperature will vary with such factors as the size of the casting, number of die
cavities, alloy being cast and machine cycle time.
The alloy is injected into the die at this exact temperature at high speeds and then rapidly
cooled for ejection. This extremely fast and repeated cooling requires careful engineering of a
complex network of internal die temperature lines.
Proper thermal balancing through the strategic placement of these lines reduces die casting
cycle time, improves casting quality, and lengthens the life of the die.
Different areas of the die can be heated or cooled to different temperatures, i.e., different cover
half and ejector half temperatures can be used to aid control of part density or surface finish.

5.3 Oil Heating Lines

In some cases differential heating of various areas of the die to produce specific casting design
features will be achieved by the use of hot oil lines in the die.
Hot oil systems heat a special oil to a given elevated temperature and pipe it through the die in
the same manner as water cooling lines. Both water cooling and hot oil heating lines may be used.

5.4 Alternate Surface Textures

Using photoengraving techniques in making the die cavities, a wide range of patterns, grainings
and textures can be selected for permanent die casting into the surface of a part. The die caster
can exhibit actual samples of the common die cast textures possible. (For illustrations of sample
textures, see the Surface Treatment chapter of Product Design for Die Castings.)

Fig. 2-11 Heat checking as seen on a casting. Fig. 2-12 Washout as seen on a casting.

5.5 Extended Die Life

While optimum die life begins with high quality tool steel, several patented processes are
available which can be used to extend the life of a die casting die. These processes involve shot
peening techniques, submersion in special baths, and chemical treatments of the die. The die
caster can discuss the projected effectiveness of such steps to reduce premature die wear in the
case of specific part design.

2-12 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

Fig. 2-13 Photos of die surface crack

patterns reproduced approximately
70% of actual size. The die steel heat
check conditions is reflected as raised
material on the surface of the casting.

Courtesy of UDDEHOLM

NADCA Product Specification Standards for Die Castings / 2006 2-13

 Tooling for Die Casting

A typical failure mode of dies is heat checking or thermal fatigue cracking.

5.5.1 Heat Checking. Die Casting tools show small cracks (network) as well as bigger (leading)
cracks after some time in use, due to thermal fatigue. Both are important to tool life.
The scale in figure 2-13 is designed to give you a combined grading using both network and
leading crack values.
Compare the scales with your tool. Give the tool a grading from both scales. Add the two
gradings. These two combined readings give you the degree of heat checking.
Determine at what point the die will no longer be useful. For critical surfaces, such as those to
be polished or chrome plated, you might stop using the die at a combined rating of six. For other
surfaces, especially those not seen by users of the finished product, the die might be used until
the rating is judged to be greater than 14. As the rating goes up, there is not only an aesthetic
loss but an economic loss in the production of the parts.
The scale also provides a concrete basis of comparison between different tools and number of shots.

6 Secondary Machining Preplanning

While most die castings are produced to near-net-shape, and many to net-shape, the close
tolerances possible with die casting and the repeatability of the process suits die cast parts to
economical high-precision secondary machining operations.
A die casting can be designed to accurately adapt to machining fi xtures by casting in locator
holes or casting a flush locating datum surface. Die castings can be drilled, tapped, reamed,
punched, or have nearly any type of machining operation performed on them.
Machining operations, including gaging and any other secondary operations that may be
required, can be performed by the die caster. Properly designing the part and the die for optimum
quality and economy in secondary machining will have an important impact on reducing final part
costs. Detailed discussions should be held with die caster engineering personnel to establish such
machining parameters as the precise location, extent, and depth of the machining required; the
surface finish required; and any other specification necessary to result in a quality component.
Decisions on special machining equipment ownership, maintenance and replacement must also
be discussed. Such matters are outlined in the Commercial Practices section of this manual.

7 Gaging Considerations

What gages will be used in casting production and in secondary machining, and what they will
check, are important elements of the die casting program.
Gages may be used to check the casting in its as-cast state and again after machining. The gage
may be an attribute gauge, which is basically a go or no-go check and results in either a good
or bad part.
A variable gage may also be employed which, used with a computer, can document variables,
collect data, and record Cpks.
More than one gage may be needed to check a casting: one to check it in its as-cast condition
and another to check the casting in a fully machined condition. There may be a need for plug and
thread gages as well as finished gages or standards for painted surfaces.
The gaging should be considered by the customer as part of the tooling package. Gaging
requirements should be resolved early by the quality assurance managers of both the customer
and the die caster, so no questions remain on meeting the part print requirements.

2-14 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

8 Inherited Tooling

In some instances a customer may transfer a die casting die from one die caster to another. This
generally will raise some operational questions for the receiving die caster of which the customer
should be aware.
The die may need to be put into a different type of die casting machine. This may require some
modifications to the dies ejector system as well as to the shot sleeve, i.e. the entry for molten metal.
The dies gate and runner system may also need to be modified to suit the new machine condi-
2
tions. It may be necessary for any residual oil in the hydraulic system of the die to be sent out for
sampling to assure that it does not contain any contaminants.
The die must be evaluated by the customer and the die casters tool room superintendent to
assure that there are no visual problems with the die. They should also determine whether the die
arrived with any required limit switches and hydraulic cylinders.
Upon this review an adaptation cost can be established and agreed upon before the receiving
die caster has invested a large amount of time and expense in preproduction work.
Checklist T-2-1, at the end of this section, will aid in addressing questions regarding transferred
or inherited tooling.

9 Engineering Consultation

The customer company, in the person of its engineering and quality assurance personnel, will
usually be requested to meet with the custom die casters engineering and quality assurance
personnel as early as possible to discuss the design and function of the part design proposed for
die casting.
They will discuss the designs function, fit and precise assembly with other components. The die
casting process uniquely lends itself to parts consolidation, decreasing the number of components
in a product assembly.
Early involvement with the die caster is essential in avoiding expensive corrective steps in later
die construction. It can often simplify product assembly and significantly reduce total product
costs.
For example, an attached hinge bracket could be die cast as an integral part of the casting. A
slight design modification could assure clearance for a close assembly.
The die caster may be able to cast an integral bearing in the part that the customer was
planning to press in. Or the die caster may be able to perform a complete or partial assembly
operation more economically, such as installing a gasket after painting the casting, and shipping
the part ready for assembly. Many die casters have in-house capabilities for operations such as
pressure testing, impregnating, machining, surface finishing and subassembly.
The experienced die caster should be regarded as a invaluable source of expertise in the die
casting production and assembly process.
Depending on part configuration, very small high-volume zinc parts, weighing fractions of an
ounce, may be recommended for production on special hot-chamber zinc die casting machines.
Such parts, usually called miniature or microminiature die castings, can be cast flash-free,
with zero draft, to very close net-shape tolerances.

NADCA Product Specification Standards for Die Castings / 2006 2-15

 Tooling for Die Casting

10 Database Guidelines

When databases are utilized, quotations for castings are often based on the assumption that any
CAD databases provided to build tooling and produce parts are complete, usable and are without
need of updating.
Databases may be deemed incomplete and unusable if:
1. The geometry of the part is not physically moldable.
2. The necessary draft and radii are not incorporated.
3. Line and surface geometry are not connected within 0.001.
Note: The database file format may not be compatible with existing capabilities and may require
a translator. STL files are usually only used for creation of prototype parts.
Any necessary database manipulation that is caused by incompleteness as described above
could add cost and extended lead-time to tooling.
If databases are designed only to nominal dimensions, tool life and casting tolerances may be
adversely impacted.
If solid model databases are used for tool construction, they should be accompanied by a
limited dimension part print (either paper or database) that contains all tolerancing information
and information pertaining to any secondary machining that is to be performed to the part.
The revision control for databases should be as agreed upon between the die caster and
customer.

11 New Die/Inherited Die Specifications

Checklist T-2-1, which follow, will aid in discussions between the customer and the die caster
regarding the important considerations in the design of a new die casting die or in the production
of parts from inherited tooling.

12 Die Life

Die casters are frequently asked the question, How many shots will I get from the die before it
needs to be replaced? or How many shots will you guarantee the die for? A better question
might be, What can we do to maximize die life and to minimize replacement costs?
Aluminum and Copper die casting dies wear out due to the aggressive nature and high melting
temperatures of the materials being die cast.
Die life is a consideration of part design, part function, internal part requirements and part
cosmetics. In general, cosmetic areas of the part do not last as long as functional areas.
The following is a suggested approach to be used by the customer and die caster at the time of
part design. The intent is to define critical areas of the die casting before the start of tool design.
This allows areas to be inserted to maximize die life and minimize the replacement costs.
First, is to develop a rating scale by which this information can be used to relate part considerations to
estimated tool life. A guideline (T-2-2) has been developed and includes; a Die Life Checklist, sample part,
example of tool steel inserting and identification matrix starting on page 2-19.

2-16 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

13 Checklist for Die Casting Die Specifications To be used in consultation with your Die Caster NADCA
T-2-1-06
Part 1 New Die Casting Dies: Items to be Addressed
In the case of new die casting dies, all of the items in Part 1, below, should be reviewed. Note, in Checklist
the case of tooling to be transferred to, or inherited by a die caster, the items asterisked (*) in
Part 1 should be addressed, plus the items noted in Part 2 on the next page.
This two-part specification
2
checklist is intended for
Type of Prototype Die Casting Die use in consultation with
New Die Production Die Casting Die your die caster prior to
estimation of new die
Cavity Steel* H13 design and construction,
Premium Grade H13 or prior to die casting
Superior Grade H13 production using inher-
Other Tool Steel: __________________________________________________ ited tooling. It should be
Certification Required: Yes No used in combination with
checklists C-8-1 and C-8-2
Cavity Steel Hardness Required: in Commercial Practices,
Heat Treat* Certification Required: Yes No Section 8.

Cored Holes* All Holes Cored

Cored Holes As Noted On Print
No Cored Holes
Die Operation Mechanical Movement
for Part Hydraulic Movement
Features* Features To Be Achieved By Secondary Operations
Estimated Monthly: _______________________________________________________________
Part Volume Annual: ________________________________________________________________
Expected Product Life: _________________________________________________
Casting Alloy* Aluminum
Copper
Magnesium
Zinc
ZA: ZA-8 ZA-12 ZA-27
Casting Weight Estimated Casting Weight: _____________________________________________

As-cast Part Mechanical Grade (Functional Finish)

Finish* Painting Grade
Highest Quality (Cosmetic Finish) For Plating, Etc.
Class of Die Unit Die Single Cavity
Conventional Die Multiple Cavity
Multiple Cavity - Family Die
Cast-In Date In Die Cavity
Insert* Other Requirements: ______________________________________________
Not Required
Cast-In Part In Die Cavity
Number* Other Requirements: ______________________________________________
Not Required

NADCA Product Specification Standards for Die Castings / 2006 2-17

 Tooling for Die Casting

NADCA Part 1 New Die Casting Dies: Items to be Addressed (Continued)

T-2-1-06 Cast-In Logo, In Die Cavity Other
Lettering* Include: ________________________________________________________________
Checklist Customer Logo Cavity No.
Supplier Logo Revision No.
Recycling Logo
This two-part specification Die Layout Customer to Approve Layout
checklist is intended for
use in consultation with
Approval by Die Caster
your die caster prior to First-Piece Customer Approval Before Production Run Required
estimation of new die Approval Run on Die Caster Approval
design and construction,
or prior to die casting Gages* Customer to Supply Special Gages
production using inher- Die Caster to Supply Special Gages
ited tooling. It should be
Trim Die Mechanical Movement
used in combination with
checklists C-8-1 and C-8-2 Hydraulic Movement
in Commercial Practices, Features To Be Achieved By Secondary Operations
Section 8. Machining No Secondary machining required
Fixtures Machining reguired, no special fixtures
Special machining fixtures required, customer to supply
Special machining fixtures required, die caster to supply
Special Items Special Items to be included in the tooling package:
_________________________________________________________________________
_________________________________________________________________________

Part 2 Inherited Die Casting Dies: Additional Items to be Addressed

In the case of inherited tooling, not the asterisked items (*) in Part 1, plus the items below.
Note that with transferred, or inherited, tooling for die casting production the existing die casting
die, the trim die, and, if required, the secondary machining fixtures, must be available for review and
evaluation to determine whether the dies and fixtures are capable of producing to specifications and
the extent of maintenance and/or rework required before the onset of production. This would include
any adaptations of the die casters equipment to accommodate production using the inherited dies.
Final production estimates will be based on this review.

Inherited Die Die Casting Die Available for Evaluation

Die to be Available for Evaluation (date): __________________________
Inherited Trim Die Not Required
Trim Die Trim Die Available for Evaluation
Trim Die to be Available for Evaluation (date): _____________________
Inherited Special Machining Fixtures Not Required
Machining Machining Fixtures Available for Evaluation
Fixtures Machining Fixtures to be Available for Evaluation (date): __________
Actual Casting Weight of Actual Casting: ______________________________________________
Weight
Size of Die Size of Casting Die (for equipment limitations): _________________________
Weight of Die Weight of Casting Die (for crane limitations): ___________________________
Availability Yes
of Die Design No
Publisher grants permission to reproduce this checklist as part of a die casting Request for Quotation or Production Specification.

2-18 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

14 Guidelines to Increase Die Life Die Life Checklist NADCA

T-2-2-06
Before the start of tooling Part
Class Consideration Guideline
1) Redesign of part to reduce or eliminate sharp internals corners or
features that will promote early cracking of the tool steel. Critical to

2) Use of special tool steels in areas where high wear is expected

A Function & 2
Cosmetic
(increases tool costs). Cosmetic,
B
3) Insert areas of cavity blocks for more economical replacement No Function
(may increase tool costs) after tool wear has occurred. Critical to
C
Function
4) Do a surface treatment (shot blasting) to the tool steel to help
reduce heat checking and cracking (adds to tool cost). Note: This Not Critical
D
will add a surface texture to the die cast part. but Functional
E No Function
5) Add a vibratory, shot blast or deburring operation to the part to
help extend tool life (added part cost).
Estimated
6) Add a machining operation to remove heat checking and/or Class Die Life/Shots
cracking in areas that are critical on the part (adds to part cost). Less than
1
7) Reclaim the surface hardness, if possible, when it drops from the 10,000
40s HRC to the high 30s HRC. 10,000 to
2
25,000
25,000 to
3
50,000
50,000 to
4
100,000
More than
5
100,000
Using the above we will develop
and itemize the areas of concern
of a sample part.

NADCA Product Specification Standards for Die Castings / 2006 2-19

 Tooling for Die Casting

IWcfb[FWhj

I^Whf9ehd[hi E#h_d]Ikh\WY[

9eic[j_Y
Ded#<kdYj_edWb

<kdYj_edWb

Cekdj_d]Ikh\WY[
Ded#<kdYj_edWb
I[Wb_d]Ikh\WY[
Using the sample, the next step is to develop an inserting plan for the tool steel construction.

JeebIj[[b?di[hj9edijhkYj_ed

?di[hj
FWhj9edi_Z[hWj_ed

;ij_cWj[Z:_[B_\[

( 9) ) ;+

' 8+ HWZ_ki

, :*

* ;+ + 9) - 9)
Last is to develop the matrix for communication of tool steel replacement needs and to develop
history on each insert. (The information shown in this example represents only what can be done.
The actual information to be included should be determined by the customer and the die caster).
Two examples of this type of matrix are shown, at the start of a new project and the other as it
may appear after the first year of production.

2-20 NADCA Product Specification Standards for Die Castings / 2006

Tooling for Die Casting

As mentioned earlier this is just a suggested approach to improving die life and reducing replace-
ment costs. Aluminum and copper alloy die casting dies do wear out. It is an advantage to both
the customer and the die casters benefit to layout a plan at the start of the project. This allows
inserts to be replaced before any actual failure thus preventing any possible loss of production.
The examples shown are only one of many possible methods to achieve this. If the customer and
die caster choose to use this type of approach, it should be on a part by part basis. The informa-
tion in the matrix should be relevant to the actual tool construction and the actual annual usage.

NADCA Product Specification Standards for Die Castings / 2006 2-21