Volume 42 - October 2020

Volume 42 - October 2020

From the Foseco Archives 01

Brand-New Innovation for The Non Ferrous
Sector: The Exothermic Feeder Feedex NF1
Arndt Fröscher, Foseco Germany

Tool Engineering - Aluminium Die Casting 05

Creative, Innovative, Attractive Engineering
C. Surianarayanan. Coimbatore
Shrikant Bhat
Head Non - Ferrous Foundry
Foseco India Ltd. Reduction of Oxide Inclusions in Aluminum Cylinder 10
Heads through Autonomous Designs of Experiments
Vijay Chavan Lubos Pavlak and Jörg C. Sturm, MAGMA GmbH,
V-Smart Thermotech Pvt. Ltd. Aachen, Germany

Pramod Gajare
Consultant Die Coating Basics, Composition, 15
Selection and Application
Mrs. N. S. Kadam Shrikant Bhat, Foseco India Ltd., Pune
Met. Dept. Govt. Polytechnic

R. T. Kulkarni Learning from Customers 23

Director Deepak Bhalerao
Arkey Conference Service Cell Business Consultants & Management Services
L.N. Enterprises, Pune
Aniruddha Inamdar
Consultant

Prof. S. K. Paknikar
Consultant

Shivaji Pawar
Director
Shiva Tool Tech

GDC TECH Journal l Issue 42, October 2020

 From Editor’s Desk

Dear Readers,

As we release the Journal Issue of October 2020, we are especially happy that we are
completing 7 years of publication. It is also quite satisfying to note that all these years we
have been able to publish the journal consistently every even month, with a solitary
exception of April 2020 due to Lockdown. This of course is possible only due to valuable
contribution from various authors from time to time, support from the industry and
appreciative readers. The Editorial Board will always remain grateful to them.

From the inception of Journal, the emphasis has always been on the technical content,
technical articles in the Journal which can be useful to the Aluminium Casting Industry
personnel. There are of course some shortcomings which we are quite aware of. One of
them is our inability to get contributors from Academia, Institutes, Faculty Members and
Students. We, however hope that in the days to come, we will be able to get some active
contribution from this segment as well.

Now, we are all looking at future with some increasing hope, as it appears that we are
nearing the end of tunnel which we are forced into over last more than six months.
Though we are still quite away from 'Old Normal', there is progressively some
improvement in the industrial and social activities over last two months.
th
So as we move into 8 year of the Journal, we sincerely wish to see some smile back in
Aluminium Die Casting Industry in near future.

GDC TECH Journal l Issue 42, October 2020

GDC TECH Journal l Issue 42, October 2020 01
GDC TECH Journal l Issue 42, October 2020 02
GDC TECH Journal l Issue 42, October 2020 03
 TOOL ENGINEERING - Aluminium Die Casting
Creative, Innovative, Attractive Engineering
C. Surianarayanan, Consultant, Tooling Soultion
E-mail : [email protected]

High Pressure (Cold chamber)

Well-engineered die Design
1. Die design
2. Die material
3. Heat treatment
4. Coatings
5. Operation/maintenance

Draft Angle
Important factor for the stress-free casting removal
from the die
• If the profile is longer and slender, it is
better to consider enough draft angle up to
3°
• But in some cases, can consider draft angles
from 0.5° to 1°
• where the height or length is approximately
equal or below 2 times the diameter / height
to travel out of the die.
Success of good casting is based on: • Thin wall sectioned ribs should be of above
• Perfectly designed product 1.5 deg
• Well-engineered die design
• Best steel used for the Die Locking Tonnage Calculation
• Perfectly heat-treated Die elements Tonnage required= Shadow Area* Specific
• Robust built Die Pressure*N
• Well prepared Aluminum alloy
• Well-built Die casting machine
• Perfect process engineering practices
Part Profile
Product design validation (DFM):
1) Part profile wall thickness & mass distribution
2) Undercuts & average wall thickness
3) Profile intricacy and internal quality
requirements
4) Possibility for fixing the ejection pin for Parting line Profile
balanced ejection
5) Gate location required to fill and parts final Shadow Area
requirement
6) Projected area for locking tonnage selection Specific Pressure is considered as per the product
7) Mass to select the Plunger diameter to QA requirements
achieve Fill ratio 600 Bar for conventional parts
8) Die placement on the Machine platen 800 Bar for airtight parts
>1000 Bar for high precision parts with high task
9) Injection centre to Platen relation
load or pressure

GDC TECH Journal l Issue 42, October 2020 04

Factor of Safety Fill ratio is the cumulative mass of :
N = 1.5 for castings of premium grade with high
strength and surface treatments cast part+ metal before part +metal after part
COLD CHAMBER LENGTH
N = 1.25 for castings requiring high mechanical
strength during field function

N = 1.10 for castings for low engineering and high

SPRUE BUSH SHOT SLEEVE
aesthetic performance
Split design pf the cold chamber can have shift in the axis
Where “N” Denotes the factor of machine safety and can shear the plunger. This will not be noticed by the
according to the casting QA needs operator but this can be the culprit for casting filling
defects.
Fill ratio of the cold chamber is an important factor
for the result of the casting. It is suggested to have the design as given in the picture.

SPRUE SHOT SLEEVE

BUSH

This design ensures the free travel as well the alignment of

the plunger inside the cold chamber. It is suggested to have
the Fitment as H7 g6 to accommodate the heat expansion
of the sleeve as well the plunger.

Runner and Gate guidelines

HPDC-It is better to select the flow in gates such that hot
alloy flows shorter distance to reach the complete profile

HPDC :

Buhler Suggestion
Fill ratio suggestion:

Scientific 70:30:00

Practical 60:40:00

thicker sections 50:50:00

There are likely chances of flash/ non filling/ air

trapped high to name some are caused by the
improper selection of the fill ratio. Sketch : 1 & 3
Here the runner design is selected to travel for the
Cold chamber is the cumulative length of the Shot longer distance may be for the reason to save the die
sleeve and the sprue bush. size as well the HPDC platen suitability in appropriate
machine.

GDC TECH Journal l Issue 42, October 2020 05

Here the flow distance is longer and alloy may Runner features and guidelines:
reduce in the temperature as well the velocity. This `Y' is better than `T' to avoid the vortex shedding
has to be considered and the runner volume to be
enhanced to suite the requirement. To shift the
final filling point far away from the casting profile it
is suggested to have the chill vent as in the sketch 3

Sketch:2
This is the best lay out to take the liquid alloy with
the appropriate velocity as well the temperature.
But the die construction n may call for a bigger
platen size which may be of a higher tonnage
machine. This will have the process cost enhanced
hence it is suggested to think of the option as in the ‘Y’ Junction ‘T’ Junction
Increases volume at the junction creating low pressure area
Reduces area and increases pressure progressively
sketch 3 at the centre of the gate

Spreader defines the trouble-free flow of the liquid

alloy inside the main feeder runners.

It is suggested to have the best flow angle to have

the volumetric flow happening from the spreader.
Sketch here explains the details

Option 1

Option 2

Guide Line to arrive the best shot weight??

Option 1:
Flow from the sleeve is suddenly restricted. This Casting Weight is the base (Let us say A Kg)
will cause high velocity by the squeezing of the
liquid alloy being forced inside the main feeder Biscuit weight---8% TO 15% OF A (This need not be
runner in the spreader. This will influence to higher than this)
flow defects as well the die erosion.
Runner weight----Minimum 25% A (this can be higher
Option 2: as required to match the fill ratio)
This will have best of flow with the support of
the good gradient to reach the sub runners with Overflow weight---- 8% TO 15% A (This need not be
the appropriate /adequate velocity to fill the higher than this)
part profile

GDC TECH Journal l Issue 42, October 2020 06

Segmental flow design:

Prepare the lay out for the best flow of the liquid
metal into the part profile of the die.

Ensure the number of gates are located to balance

the filling.
Tapering the runner profile as suggested is to create the
Maintain the same gate thickness only to have the flow velocity of the liquid metal as it comes out from
gate velocity as same in all the gates.
the biscuit and the main runner. This is essential
Gate width & the runner width can be to the because the Plunger velocity with the machine
available space to flow the maximum possible hydraulic do not support this and the flow of alloy back
volume of the liquid alloy to fill the part pressure Can only support this.
volumetrically.
Overflows shapes for the best performance:
Then prepare the matrix and study the weight of
the segments to be filled by the respective runners.
This will guide to decide the runner dimension to
match the volumetric filling

• The shape and dimensions of an overflow.

• A = Land length (2 – 5 mm);
• B = Overall length of the overflow gate (5 - 8 mm)
• C = Overflow gate height (Al 0,6 – 1,2 mm, Zn 0,3 –
0,8 mm, Ms. 0,8 – 1,5 mm). Vent height is
Gate location are to be fixed for shortest travel of as follows: Al 0,10 – 0,15 mm, Zn 0,06 – 0,10 mm,
the hot alloy in to the profile. Ms. 0,1 – 0,15 mm.
Gate thickness should be the same in all the gates
Width can be to the need of the segmental filling

Each gate should fill the weight of the segment covered

with in the Fill time specified.

Calculated gate area is for the lowest and can be higher

than this and never should be lower than this.

Maintain this in the runner design for the best of

flow results:

GDC TECH Journal l Issue 42, October 2020 07

 Recommendation of a steel mill

(Suggested to consider at least 70% to 80%)

`A' Cavity depth

`B 'Insert Thickness

Waterlines for the thermal management of the

die:

This sketch is of guidelines need to be applied PL = Parting Line

when adding waterlines to the cavity. WL=Water line

A case study of a runner and the plunger decision for • Aluminium Structural parts which will have
a best forming die to achieve techno commercially higher section thicknesses will be Cast in
viable Liquid Forging principles against the Squeeze
casting, DC & LPDC
Shot weight with Ø 70 mm Plunger: 880 grams
• Fill ratio is 27% of the cold chamber • Slurry casting will catch up higher to replace
• Runner weight should be 126 grams thixo casting as this can be carried out in the
same machines with some attachment of
Shot weight with Ø 60 mm Plunger: 559 grams peripherals
• Fill ratio is 24%
• Runner weight should be 63 grams
• Aluminium alloy saving will be 321 grams per
shot
• Saving is higher in the Ø 60 mm Plunger
design
• Fill ratio is also Ok for the best filling
Conclusive suggestion is to go for Ø 60 mm Plunger
For best of the filling and economical shot weight.
This will be of highest cost benefit decision

What will be the future and for which we have get

Knowledge to cater to:

• Weight being the critical subject to be

discussed whether Magnesium will have
more scope against Aluminium

GDC TECH Journal l Issue 42, October 2020 08

Tool Design is important Simple example!!

If a Foreign Supplier Pays 4$ per hour for the

WHY??? technician, it is said in India we pay lower than
1$per hour. In this case how they can be cheaper is
Any development is successful only by implementing it that if they take 4 hours for a job, we take say 20
in the field of public utilisation. hours then he is cheaper than us by 5 times.
How tool making services in this scenario? Prototypes cannot do that in mass numbers. Hence
tooling is the solution for getting the result of
Commercial tool making in India has not flourished successive repeated production of the parts
well but for few players. Actual needs are met by manufactured in sheet metal, Plastic & Aluminium.
Imports to major volume facing lots of difficulties but
compromising on the best timelines adhered by the It is time for us to gear up to the need of the hour.
suppliers.

Available commercial tool rooms are not financially &

technically competent to that of the import suppliers.

How Can this be Bridged?

QCD is the only way out. I would say DCQ is the correct
word to mention. Cost is the criterion which is
enhanced mainly by timeline which will determine the
cost as by product.

Published
DIRECTORY Now
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INDUSTRY o
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What's app on
Mobile +91 97647 11315 FORGING
to Book your Order or INDUSTRY
Email us Organised By

on [email protected] A Division of ARKEY TECHNICAL TRAINING & RESEARCH INSTITUTE (TRUST)

* Courier Charges at actual

GDC TECH Journal l Issue 42, October 2020 09

 Reduction of Oxide Inclusions in Aluminum Cylinder Heads through
Autonomous Designs of Experiments
Lubos Pavlak and Jörg C. Sturm, MAGMA GmbH, Aachen, Germany

Abstract properties, or, especially in thin casting walls, they can

cause leaks.
Oxide inclusions, which are created during the pouring
process of aluminum alloys, are the main cause of leaks The damaging effects of oxides on the quality of
in castings. This contribution shows how the castings can in the real world only be evaluated through
integration of autonomous design of experiments experiments, i. e. leak tests on castings, after castings
(DOEs) into the casting process simulation tool have been produced. The location of oxides, their
MAGMASOFT® provides the basis for the evaluation distribution and the leaks they cause, are difficult to
and subsequent optimization of process parameters in predict and are almost impossible to quantify.
the melt transport and pouring process, which are L i te rat u re 1 , 2 d e s c r i b e s p o te nt i a l ca u s e s a n d
responsible for the creation and distribution of oxide mechanisms that create oxides during the melting and
inclusions. At the same time, quality criteria describing pouring processes of aluminum alloys. However, the
the creation of oxides during the casting process of qualitative and quantitative evaluation of each root
cylinder heads was evaluated quantitatively. The cause for the creation of oxides in each step of the
utilization of autonomous DOEs creates variations of production process of cylinder heads has so far not
t h e gat in g system a n d p ro c es s p a ra m eters been comprehensively evaluated.
autonomously. It will be shown that autonomous DOEs
are leading to optimized gating designs and process An efficient evaluation of the many different impact
parameters resulting in a significant reduction of factors of the mold filling process on the quality of a
oxides in castings. The experiments supported by cylinder head is only feasible through the utilization of
simulation were accompanied and validated by high- casting process simulation. The simulation of flow
speed video technology and the PREFIL-measurement phenomena and the mold filling process is an accepted
technology. standard procedure in the industry. Different
simulation methods have been proposed in the last few
Keywords: aluminum casting, cylinder head, oxide years to describe the creation and transport of oxides
inclusions, Design of Experiments, virtual during the mold filling process3-7, however, many of
experimentation, autonomous optimization, gating these models are only available as 2-dimensional
system models. Due to their complexity and the computing
demands, they are not applicable to the specific
Introduction conditions of aluminum alloys and are almost useless in
foundries due to their extremely long calculation times.
Oxide inclusions, which are created during the pouring
process of aluminum alloys, are deemed the main The current version of the simulation software
cause of leaks in thin-walled aluminum castings like ®
MAGMASOFT offers an easy to use, meaningful, and
cylinder aluminum melts, is not dissolved or re-melted quantifying option to evaluate the potential of oxide
due to its high melting temperature and remains in its creation during the mold filling process of complex
solid state inside the casting. Any pouring process castings. The complete integration of autonomous
leads to turbulence at the melt surface. This leads to a DOEs by enabling autonomous optimization
break-up of the oxide skin, which then is entrained into technology leads to the development of optimized
the melt. Oxide skins lead to a material separation gating systems and process parameters in a very short
within the microstructure, which, depending on their time frame, which can even be utilized early in the
size, can cause a reduction in local mechanical design process of a casting.

GDC TECH Journal l Issue 42, October 2020 10

Experimental Melt Quality Evaluation

The melt quality was experimentally evaluated for different process steps. The PREFIL system used for this
evaluation is based on the filtration of a liquid aluminum sample, which is passed through a ceramic filter under
controlled conditions. The qualitative evaluation is performed on samples, which are extracted near the filter. The
number, thickness, and length of oxide particles were evaluated using metallographic methods (Figure 1).

Figure 1. Measured number of oxides in the melt (PREFIL-method) for different process steps in two cylinder head
production lines A and B: The red line marks the limit of 50 oxide skins per kg of melt.

Samples #1 through #5 have been taken from a cylinder head production line (A) with its melt being composed of
84% virgin alloy and 16% re-melt. Samples #6 through #8 are from a second production line (B) composed of 45%
virgin material and 55% re-melt.

The number of oxide skins found in samples #1 and #6 significantly exceeds the established limit of 50 oxide skins
per kg of melt and is, therefore, not acceptable. Melt transfer processes between the furnaces cause these
extremely high values, especially when the transport ladle is emptied. The amount of oxide skins inside the furnace
(sample #5) is still a little above the critical limit at the end of the pouring process. The oxide skin content of the melt
can be reduced after the transfer processes though the establishment of sufficient holding times before or after the
degassing treatment. A significant reduction in oxide skins is shown with the implementation of such (samples #2,
#3, and #7). The results confirm that it is desirable to utilize a turbulence reducing transfer method, especially when
emptying a ladle.

Experimental Evaluation of Flow Phenomena

High-speed video technology, providing up to 1,000 images per second, was used for the qualitative evaluation of
flow phenomena during the different process steps (Figure 2).

Figure 2. Evaluation of transfer processes with high-speed videos:

Filling of transfer ladle (left), filling of holding furnace (center), filling of pouring ladle (right)

GDC TECH Journal l Issue 42, October 2020 11

Transporting the melt from the melting furnace to
the holding furnace happens via an extended
pouring spout when both are in close proximity, or a
transfer ladle when a bigger distance needs to be
covered. After the melt treatments, the melt will be
transferred into the mold via a pouring ladle. With
each transfer, turbulences are created on the melt
surface. This is a main cause for the creation of new
oxides within the melt.

The videos show the mixing of the oxide foam

swimming on the melt surface with the falling melt
stream clearly visible. The observations from the
transfer processes match the results of the PREFIL-
measurements. All samples derived from the spout
or the transfer ladle after filling of the holding
furnace show values in excess of the critical limit
(see also Figure 1). After the melt treatment inside
the pouring furnace (degassing and holding), the
number of oxide skins found in the melt is reduced.

The filling of a cylinder head creates a complex flow

process. Turbulences caused by the free falling melt
in the gating system and when exiting from the
gating system into the mold cavity cannot be
completely eliminated, but can be reduced. The
melt then flows through the different cores.
Controlling the flow and reducing turbulence in the
complex cavities of a cylinder head with wall-
thicknesses of 4 mm requires a lot of experience
and a fundamental understanding of flow
phenomena.

During the design of runners and the location of

gates between the runner and the casting, it is
essential to consider melt velocities and to
establish laminar flow conditions to avoid
undesired flow phenomena when filling the cores.
A non-optimal flow direction during the mold filling
might lead to a local premature solidification on a
core's surface. This leads to an oxide skin, which will
be entrapped during the subsequent filling process
and will remain in the casting (Figure 3). The
intricate inside contour of the mold and the thin
walls of the cylinder head increase the risk of oxide
inclusion defects and resulting leaks, as trial runs
with gravity cast cylinder heads confirmed (Figure Figure 3. Change in flow direction during the mold filling
4). process of a cylinder head: The cover core was modified
to allow high-speed videos of the melt flowing from the
runner through the gates to be taken.

GDC TECH Journal l Issue 42, October 2020 12

a) Cut throughs leaking cylinder head b) Fracture analysis through leaker c) Microstructure analysis

Figure 4. Root-cause analysis on a leaking cylinder head: Leak tests under water indicate two leakers
through rising bubbles (a). The fracture analysis shows an oxide skin spanning the entire thin wall (b).
The microstructure analysis confirms the cause for the leaker (c).

Quantitative Analysis of Oxide Creation and Figure 5 shows examples of such quality criteria: the
Optimization Opportunities through the simulated entrainment of oxides through tracers, the
Utilization of Casting Process Simulation calculated amount of entrapped air during the filling of
the pouring ladle, and the velocity distribution inside
Casting process simulation provides the the melt during the filling of the cylinder head. It is
quantitative impact evaluation of process essential for all calculated quality criteria that they
parameters on the creation of air entrapment and provide quantitative results. With that, the impact of
oxides for the entire casting process – from changes in the gating system or process parameters
melting all the way through to pouring the ( d e s i g n p a ra m e te rs ) ca n b e e va l u ate d a n d
casting. autonomously optimized through objectives defined in
the casting process optimization program.
Several quality criteria are used to evaluate the
total amount of entrapped air and resulting 5. Virtual particles in the melt (tracers), which are also
creation of oxides: reviewed to evaluate the flow during the mold filling
process. These particles can also experience buoyancy
1. The amount of entrained air during the and float or sink depending on their assigned mass.
mold filling process
Figure 5 shows examples of such quality criteria: the
2. The accumulated free melt surface over the simulated entrainment of oxides through tracers, the
entire filling process calculated amount of entrapped air during the filling of
the pouring ladle, and the velocity distribution inside
3. The amount of time the melt is exposed to the melt during the filling of the cylinder head. It is
air throughout the filling process (criteria 2 essential for all calculated quality criteria that they
and 3 are indicators for the tendency to provide quantitative results. With that, the impact of
create oxides) changes in the gating system or process parameters
( d e s i g n p a ra m e te rs ) ca n b e e va l u ate d a n d
4. A criteria function depicting the locations autonomously optimized through objectives defined in
where air is entrained during the mold the casting process optimization program.
filling process

5. Virtual particles in the melt (tracers), which

are also reviewed to evaluate the flow
during the mold filling process. These
particles can also experience buoyancy and
float or sink depending on their assigned
mass.

GDC TECH Journal l Issue 42, October 2020 13

 b) Free melt surface c) Location of air entrainment
and oxide particles

Figure 6. Transfer of melt from melting to holding

furnace. Criteria were calculated after 30 s filling time.
Simulated air inclusion distribution during filling (a),
display of free melt surface including the entrainment
of oxide particles (b), amount of entrapped air shown
in center cut through holding furnace (c).
Figure 5. Examples of quality criteria of a
casting process simulation tool, used for the The simulation results show how air is entrained in the
evaluation of oxide creation tendency, oxide melt, when the aluminum stream dives into the melt
entrainment (left), entrapped air (upper right) inside the holding furnace (Figure 6a). This process, as
and flow velocities (lower right). well as the movement of the entrained air inside the melt
that is affected by its buoyancy and convectional forces,
are causes for the entrainment of oxides into the melt
The first casting process simulation evaluated
(Figure 6 (c)).
the transfer process from a melting furnace to
a holding furnace. The dimensions of the
The amount of oxide inclusions inside the melt at the end
holding furnace are 60 cm (1,969 ft.) for the
of the holding furnace filling derived from the simulation
diameter and 150 cm (4,921 ft.) for its height.
results, confirms that a large pouring height leads to the
The total fill time is 60 s.
entrainment of oxides, which are created on the melt
surface through the metal stream. Therefore, it is
essential to establish transfer processes that minimize
the entrainment of air and the creation of oxides. It is also
advisable to place the casting's pouring location as close
as possible to the holding furnace, so the use of transfer
ladles can be eliminated.

..............To be continued in next issue

GDC TECH Journal l Issue 42, October 2020 14

 Die Coating Basics, Composition, Selection and Application
Shrikant Bhat, Head Non-Ferrous Foundry
FOSECO INDIA, Pune
E-mail : [email protected]

Background: modified over the years to satisfy and address specific

customer requirements. The products have also
Close to 40% of Aluminium castings produced evolved over time to reflect the change in casting
globally are made by gravity die casting and low processes and productivity requirements.
pressure die casting processes. It has always been
recognized but less internalized that a major Typically, a die coating for a gravity or a low pressure die
contributor to the successful manufacture of would consist of three main ingredients, a filler
quality die casting parts is the die coating. material (e.g. talc, graphite, mica, Titanium Oxide, etc.),
a binder (e.g. sodium silicate) and a carrier, mostly
In addition to acting as a parting agent between the water.
metallic die and the solidifying Casting, main
functions of a die coating can be summarized as: Specialized binders have been developed for improving
the bonding and hence the life span of the coatings.
· Insulation control
The prime function of the coating will decide the type
· Release from the die
and grading of the filler used or vice versa.
· Encouragement to metal streams to fill thin
sections fully Die Coating Basics, Composition, Selection and
· Control of surface finish and texture Application
as· Soundness (feeding ability) of cting
Therefore, based on the preliminary functions or the
basic ingredients of the coating, traditional die coatings
can be classified into three distinct product types:

· Insulating coatings
· Conductive coatings
· Lubricating coatings Insulating Coatings:

This is the most commonly used range of the three

groups. These coatings are essentially insulating in
nature and help maintain the temperature of metal
flow and therefore maintain the fluidity of metal during
the filling of the mould.

Composition and Classification: The insulating characteristics of the coating come

partly from the constituents of the coatings and partly
The use of die coatings has been widespread in from the fineness of the particles. The most commonly
the foundry industry for years together. used ingredients being Talc, Lime stone, Mica, Quartz,
etc.
Though the basic functions remain one or
combination of the functions mentioned Similarly, surface finish is also a combination of the
above, the traditional products are now ingredients, the application and the particle size.

GDC TECH Journal l Issue 42, October 2020 15

Flat-shaped filler particles lead to smooth surface (e.g.
DYCOTE 39) whereas Grain-shaped filler particles lead
to rough surface (e.g. DYCOTE 34)

The surface roughness or fineness is generated by the

particle size of the refractory fillers and varies between
10 and 100 microns as per the requirement.
Figure: With increasing coating thickness, the insulation (below)
In general, the coarser the particle size of the coating
and hence the Fluidity (Filling of casting above) is improved
or the refractory filler, the higher will be the insulation
effect, since the coarser size of the particle grains will 30

generate larger air pockets between the metal and the 25

die surface. It would therefore help in filling of the die 20

cavity relatively easily. 15 Insulation Value

10

However, on the contrary, the coarseness would also 5

0
impact the surface finish of the casting. Coating Thickness

Thus, selection of a die coating, is almost always a Conductive coatings or lubricating coatings:
compromise between the required surface finish of In certain applications it may be necessary to apply
the casting and the filling of the mould / die cavities. heat conducting coatings to increase the rate of heat
transfer and encourage rapid cooling.

Use of Graphite based coatings for this purpose is very

common. Almost all these coatings are graphite based
and thus they can also be simultaneously used for
lubrication of moving parts or metal cores.

Selection of die coatings

A number of factors must be taken into consideration
when selecting a die coating:

Firstly, the section thickness of the casting; one of the

main properties of a coating is its ability to facilitate the
filling of the molten metal in to the die. If the casting
has a thin section, then the die coating with high
insulation properties and coarser particle size should
be considered.

Second important criteria for casting acceptance is the

Fluidity and Coating Thickness:
surface finish. However, as discussed above, the
surface finish of the coatings and insulation provided
With increasing thickness of the coating, the heat
by them is almost inverse. The balance of surface finish
transfer from the molten metal through it to the
and insulation will therefore always be a compromise.
mould gets reduced in a direct proportion, but only
up to a coating thickness of 300 Microns. After
The selection of the die coating is also decided by the
around 250 to 300 Micron thickness, the insulation
geometry of the casting. A coating is therefore also
properties get almost flattened to thickness.
critical for efficient feeding and maintaining the flow.
For feeding isolated thick sections in a casting, a
specific coating thickness may be required which gives

GDC TECH Journal l Issue 42, October 2020 16

a greater insulation to help directional solidification. In Die Coating Thickness gauges:
a casting having uneven section thicknesses, For generating the thermal gradient within the die, it is a
directional solidification patterns may be promoted by common practice to build different thicknesses of coating in
using different die coatings or different thicknesses of the casting profile so as to attain a directional solidification
a suitable insulating coating. pattern.

Where a casting has very small draft angles and release Various types of Coating thickness gauges help check and
of the casting from the die is an issue, a coating with control the thickness.
good releasing properties may be required. A coating
based on Titanium Dioxide or a combination coating in
the form of a graphite coating on a regular insulating
coating can be considered as a very primary practice.

Finally, the casting process will also influence coating

selection.

e.g. low-pressure castings may need a different coating

or a different coating practice than gravity castings
operated manually that will need a robust coating in
comparison.

By carefully selecting the die coating with the required

features, optimum performance in terms of filling,
surface finish, directional solidification or release can
be achieved.

Process control:
In order to achieve the optimum performance from a
particular coating, the preparation, mixing and
application of the coating is very critical, too. A
systematic and dedicated die coating station under the
control of a skilled and trained operator enables the
foundry to maintain the preparation and application of
FIGURE: Different Types of Coating Thickness Gauges
coating under close control.
New Developments
To cope with increasing productivity trends in foundries
Quality checks like Density or Solids content may be
new ranges of coatings are being developed which
made for the Die coating products, but may fall beyond
would provide longer lives and better performance of
the scope of a busy producing foundry.
the coatings with minimal maintenance.
Mixers:
Development and use of different types of binders
The ingredients of the coating in concentrated
and carefully chosen grading and specifications of
and diluted condition would tend to settle and
filler additives is thus critical to improve life and
separate over period of time. Therefore, the use of a
performance.
proper mixer to ensure that the coating is not only
mixed well but is also held in suspension during the
Differential thermal gradients may be developed by
working period is essential to keep the performance of
using the highly insulating coatings developed for
the coating mix consistent. The speed of the mixer is
improving the feeding capacity of risers. This recent
critical not to break the solution or the die coating.
development helps to improve the yield and reduce the
shrinkage rejections.

GDC TECH Journal l Issue 42, October 2020 17

Another popular development is the Long Life Die
Coatings. Best Practice for Die Coating Spray:

Advantages of Long Life DYCOTE die coatings

· Improved Productivity - Dies run for longer and
hotter and so the frequency of stopping
production to change to a newly coated die is
reduced.
· A reduction in scrap on startup of a newly
coated die: It is common when a newly coated
die is first cast that the temperature profile may
not be correct. Shrinkage or mis-running
sometimes results. With a less frequently
coated die fewer problems are created.
· Reduction in frequency of coating leads to a
reduction in labour required in die preparation.
· As the Long Life die coating is tougher and more
wear resistant the die will run longer at the Precaution: The distance between the spray gun and
optimum thickness and condition of the the Die face is critical, since at shorter distances, the
coating, resulting in better quality castings. die coating spray may not stick to the die and may get
· With the special composition of Long Life die bounced back, while at longer distances, the filler and
coatings there is less likelihood of settling and binders may not reach the die face and water would
segregation during mixing. get evaporated.
· Reduction in frequency of die cleaning will
result in less die wear, improved die life and Spray Distance v/s Abrasion:
consistent casting definition.
· Foundries will traditionally touch up the
coating on the die to extend the coating life,
without removing and recoating. The amount
of touching up required will be far lower with
Long Life die coating.

Typical Long Life Die Coat Application Practice:

· Generally, best results are achieved with

dilution rates of around 1 (Die Coating): 3
(Water)
· For touch up and repairs, dilutions of 1 (Die
Coating): 4 or more (Water) should be used
· Preheat the die assembly to 200 - 250ºC
· Spray the diluted die coating on to the die at
200 - 250ºC
· Cure the Die Coating at 400-450 Deg C just over
one hour
· Curing is critical for the life span of the Long Life
Die coating
· Start casting

GDC TECH Journal l Issue 42, October 2020 18

Conclusion: References:
Thus, a carefully chosen, prepared and applied die
coating will not only provide a superior surface The information and discussions herein are based
finish of casting, but would also help in improving on various case studies, experiments, FOSECO
the feeding of the casting providing directional Literature: Foundry Practice, Manuals, Handbooks
solidification, improve productivity by reducing and the FOSECO wisdom over years.
downtime and improve the die life due to reduced
die coating maintenance.

ANNEXURE: Typical issue faced in Die coatings and general remedies:

DIGITAL TRADING PLATFORM

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Connecting You With The Metals Industry Connecting You With The Metals Industry

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Daily Metal Scrap Prices Scrap Exporters & Importers
Company Proles Scrap Yards / Traders
Equipment & Machinery Ingot / TMT / Billets Manufacturers
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producers from USA, UK, Canada, Spain, Italy, UAE, Australia, Singapore, Belgium, New Zealand, Malaysia, India, Bulgaria, Poland,
Romania, Hong Kong and other countries are using Loha Platform to post their offers & requirements on regular basis.

GDC TECH Journal l Issue 42, October 2020 19

When You Think Foundry..... Think KELSONS...!

Centralized Software System with All Digital Equipment TESTING EQUIPMENT

Digital Digital Digital MADE IN
Compactibility Cum Squeezer Wet Tensile Tester Moisture Tester
INDIA

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Hall No-6
2020 STALL-G-8
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PH. : +91 230 2469067, 2469079 Cell : +91 9422582869
Design FLASH-99 22 22 7007

EXPORTS : Malaysia, ,Syria, Dubai, Iran, E-mail : [email protected] www.kelsonssandtesting.com / www.kelsonsfoundryequipments.com

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We Also Manufacture Foundry Machinery, Metal Testing Equipment.
 Online Webinar Held for Aluminium Foundries
1. Defect Analysis And Remedial Measures – 22 & 24 July 2020
Faculty : Mr. V. G. Patil, Consultant (Ex – KOEL)

th
2. Importance Of Release Agents In Aluminium Die Casting Process - 11 August 2020
Faculty : Mr. Ashok Konduskar, Technical Manager -India, Middle East & Africa region , AAC Surface
Treatment/Cleaners & Lubricants

th th
3. Casting Defects In Aluminium High Pressure Die Casting (Two Sessions) - 19 & 20 August 2020
Faculty: Mr. Rajesh R Aggarwal, Director, TechSense Engineering Services

4. Machining & Automation Solutions For The Die Casting Industry - 24th August 2020
Faculty: Mr. Jagannath V, Business Head, m2nxt Solutions – A BFW subsidiary

5. Practicing Of OEE (Overall Equipment Efficiency) Matrix And Cost Reduction - Operating Expenses Reduction"
th
4 September 2020
Faculty : Aasheem Samadarr, Founder-CEO, EBIT>Management Consultant

6. Panel Discussion for Auto Comp manufacturers, theme was “GO GLOBAL INDIA Demonstrate Competitiveness
th
& Capabilities - 6 September 2020
Panelist are:
Mr. Hrishikesh Kulkarni, Valeo Group Purchasing Director India, VALEO INDIA PVT. LTD.
Mr. Mohan Kadam, General Manager, DANA INDIA PVT. LTD.
Mr. Nagaraj P. SONALIKA ,
Mr. Shankhadeep Mukherjee, Team Leader, CRU ANALYSIS & CONSULTING (INDIA) PVT. LTD.
Mr. R. Pattabhiraman, Tech Expert - Casting & Forgings , Global Core Powertrain STA, FORD MOTOR PVT. LTD.
Panel Co-ordinator :
Mr. Deepak Mahajan, Management consultant, domestic & international business development for auto component manufactures

th
7. Die Coating Basics, Composition and Application - 12 September 2020
Faculty: Shrikant Bhat, Head Non-Ferrous Foundry, FOSECO INDIA

8. NEW PRODUCT DEVELOPMENT - 18th September 2020

Faculty : Sanket Anil Kulkarni. Director operations, Pooja Castings Pvt Ltd.

GDC TECH Journal l Issue 42, October 2020 20

 Upcoming Webinars (Proposed)
MULTIPLE SESSIONS PROGRAMMES 4. HPDC Machine Maintenance

1. Non Destructive Testing for Aluminium 5. Problem Solving Techniques

Castings · 7 QC Tools
· Methodology of use
2. Metallurgy of Cast Alloys · Examples
· Effect of Alloying Elements & Phase · Case Studies of use in Aluminium Foundries
Diagrams – Two sessions
· Heat Treatment of Aluminium Alloys 6. Process Control for manufacturing of Quality
– One Session Castings.
· Raw Materials
3. Comprehensive Die Design PDC · Melting & Metal Treatment
· Basics of Die Design for Aluminium · Core shops – Core Boxes, Sand
HPDC · Heat Treatment
· Selecting right material for each die · Die Preparation and Maintenance
parts and its recommended · Fettling, Shot blasting, Impregnation
treatments
· Simulation for optimisation – A Die B. SINGLE SESSION PROGRAMMES
Designers' guide 1. Costing
· Exploiting 3D Modelling software for 2. Cost Reduction – Operating Expenses
maximum benefits. Reduction.
· Design for Manufacturing and 3. Productivity Improvements
maintenance 4. Yield Improvements
5. Low Cost Automation
6. Methoding Cylinder Head

PROFICIENCY IMPROVEMENT PROGRAMME

2 Weeks Certicate Course for
FRESH WORKING ENGINEERS
To MOVE TOWARDS NEXT LEVEL
Dura on: Daily Two hours in the evening of 3rd & 4th Week of November 2020

Panel Discussion
Theme : “Uncertainty in Manpower, Demand, Capacity, Utilisation and Quality Demands by the Buyers” – 1st November 2020

GDC TECH Journal l Issue 42, October 2020 21

 Look forward for the Dates
ANNUAL EVENT
GDC TECH 2020
Technical Conference

Theme : Aluminium Cas ngs - The Decade ahead

* Technical Presenta ons by experts

* Project Presenta ons

* Panel Discussions

* Technology Day

Project Competition
The project competition will help in developing good foundry
people who will contribute significantly to the well-being of the
companies. This award has been sponsored by 'Aurangabad
Electricals Limited'.
...looking forward always!

2019

Roots Cast
Pvt. Ltd.

Tata Motors Ltd.

Best Casting Award

GDCTECH has a motto to motivate the die casting industry to
Dr. Dinesh & Ramesh
improve their systems and processes which lead to significant Engineers Pvt. Ltd.

enhancement of performance parameters such as quality,

cost, delivery and development. As a part of this motto 'Best
Die Casting Award of the Year' has been instituted. This award
has been sponsored by 'Aakar Foundry, Pune'.
Sentinel
Manufacturing India Pvt. Ltd.

22
GDC TECH Journal l Issue 42, August 2020
 LEARNING FROM CUSTOMERS
Deepak Bhalerao
Business Consultants & Management Services
L.N. Enterprises, Pune
E-mail : [email protected]

As is said 'Learning Never Ends'. There is always a Working with them very closely helped us to
scope to learn from others when we interact with improve our operations & this laid Foundation for
them, Listen to some one or only observe someone. us to go ahead & become the first Indian Company
in our category of product to get QS9001
I believe, customers are also a very good Source of accreditation. This certification & those we were
Learning, which can help you improve your Product, supplier to this customer became our Selling
Processes, and Attitudes etc. proposition to acquire new customers.

I am sharing two such examples which changed our 2) The Second case is again on the Learning from
Organization Chemistry to a large extent and helped customer about process improvement.
us change our trajectory of Growth path.
As you all may be aware, most of the
1) I was working for an Auto Component manufacturers are working on improving the
Equipments in terms of Life, Fuel Efficiency, Noise,
Manufacturing Company based in Pune,
Vibration, Weight Reduction etc.
pretty well known and we had achieved a
name for ourselves in our domain.
We were working with one such company they
wanted the products to be supplied in very close
We were under the impression that we have tolerances to Reduce Friction, Wear and Tear of
done great job and started to become mating parts as also the noise levels. We were not
contended. Then the time came when the able to achieve the tolerances they had
Leadership at the top was reshuffled. demanded.

The new Leader wanted us to acquire new However, after working closely with them we
customers and probably that was the time, understood the Technology of Selective assembly
without which survival in next few years through selection of tolerance Bands and creating
would have become difficult. matching groups of Mating parts.

This was the Era Post Liberalization of This again helped us improve our Manufacturing
Economy. There were Joint ventures getting Process and Be Ready to face Next Generation
established with overseas Partners. Equipments demanding Newer Technology.

We started working with one such Jv for Thus when we work closely with the customers,
developing components for them. (Their we Learn New Technology and improve overall
process was to first do Dip Stick assessment operation and business.
of the Company).

When they visited our facility the team

consisted of R & D and QA persons. During
The more you engage with customers, the
their visit we learnt the concept of Six-Sigma, clearer things become and the easier it is
Critical, Minor Dimensions, Millipore tests & to determine what you should be doing
its importance etc.
....John Russell

GDC TECH Journal l Issue 42, October 2020 23

When You Think Foundry... Think KELSONS...!

Metal Testing Equipment

Mechanical, Digital, Computerized
MADE IN
Brinell Hardness Tester
(Digital) INDIA

Universal Testing
Machine (Electronic)

IFEX
Hall No-6
2020 STALL-G-8
Design FLASH-99 22 22 7007

EXPORTS :
Malaysia, ,Syria, Dubai, Iran, Saudi Arabia, KELSONS METALLURGICAL EQUIPMENT
Thailand, Egypt, Uganda, Germany, Baharin, G-35, M.I.D.C. Shiroli, Kolhapur - 416 122 Maharashtra. (INDIA)
Turkey, South Korea, Bangladesh, Nigeria, PH. : +91 230 2469067, 2469079 Cell : +91 9422582869
Oman, South Africa, Croatia, Finland, Vietnam E-mail : [email protected] www.kelsonssandtesting.com / www.kelsonsfoundryequipments.com
We Also Manufacture Foundry Machinery, Metal Testing Equipment.