Chapter 09

Casting Examples
Aluminum
Pistol Frame Rocker Arm Rear Axel Thrust Rod 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
section
9-2
9-2 9-2 9-2 9-3 9-3 9-3 9-4 9-4 9-5 9-5 9-5 9-6 9-6 9-6 9-7 9-7 9-7
Magnesium
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 Rear Frame Cross Car Beam for Instrument Panel
9-8
9-8 9-8 9-8 9-9 9-9 9-9 9-10 9-10 9-10 9-11 9-11 9-11
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
9-12
9-12 9-12 9-12 9-13 9-13 9-13 9-14 9-14 9-14 9-15 9-15 9-15 9-16
ZA (Zinc-Aluminum)
Tool Housing & Components Transmission Shift Selector Tube
9-16
9-16 9-16
Notes
9.17
NADCA Product Specification Standards for Die Castings / 2009
9-1
Casting Examples
Aluminum
Part Name: Application: Alloy: Comments:
Pistol Frame 0.22 Caliber Pistol A380 Part was previously machined from stock. This is the first aluminum die casting used by Smith & Wesson. Smith & Wesson
Part Weight: 0.35 lbs.
Customer:
Aluminum
Rocker Arm Honda Civic Engine 383 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 requirements Honda of America Mfg., Inc.
Customer:
Aluminum
Part Name: Application: Part Weight: Alloy: Comments:
Rear Axel Thrust Rod BMW E70/E71 Vehicles 0.79 lbs. 380 Thin wall casting reduced original three-piece design to a single part and mass was reduced by about 50% using a high pressure process BMW
Customer:
9-2
Casting Examples
Aluminum
Endbell Air Compressors 380 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. Devilbiss Air Power Company
Customer:
Aluminum
Engine Base Bracket Honda Accord Engine 6.2 lbs. ADC3SF jointly developed with Honda, compatible with SF36, Aural 2 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%. Honda
Customer:
Aluminum
Water Passage Honda Civic Engine 383 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. Honda of America Mfg. Inc.
Customer:
9-3
Casting Examples
Aluminum
Part Name: Application:
Heat Sink Front & Back Garmin G-1000 Flat Panel Flight Display 360 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 its 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. Garmin International
Part Weight: 1.91 lbs. Alloy: Comments:
Customer:
Aluminum
Chassis Human Transporter 380 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. Segway
Customer:
9-4
Casting Examples
Aluminum
B Pillar Automotive Structural Support 380 A new part cast for automobile body framing support application. Yields weight savings benefit over fabricated steel components.
Customer:
Aluminum
Trimmer Deck Housing Walk Behind Trimmer 380 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.). Garden Way, Inc.
Customer:
Aluminum
RFU Enclosure Microwave Communications 413 Formerly produced as an investment casting. Provides heat dissipation and electrical conductivity. Die casting reduced lead time and machining requirements. Harris Corporation, Microwave Communications Division
Customer:
9-5
Casting Examples
Aluminum
Impeller Industrial/Commercial Blower A380 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. Ametek Rotron
Part Weight: 10.29 lbs Alloy: Comments:
Customer:
Aluminum
Lower Crankcase Motorcycle LM2 to JVM Specifications Redesign of original T120, 1959 Bonneville high performance version of Triumphs 650cc twin. Eliminated costly secondary machining operations, additional engine parts and fully utilized the benefits of high pressure die casting process. Triumph Motorcycles
Customer:
Aluminum
Differential Carrier Independent Rear Suspension ADC-12 -T6 Heat Treatment 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 Visteon Corporation
Customer:
9-6
Casting Examples
Aluminum
Beta Crankcase Right & Left Motorcycle 383 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. Harley-Davidson
Customer:
Aluminum
Scooter Monocoque Frame Honda Scooter Super Sport JIS ADC12; 383 equivalent Previously fabricated from steel sheet stamping and pipes. Die casting provided weight savings and cost reduction. Honda R&D Co., Ltd.
Customer:
Aluminum
Rear Wheel Drive Northstar Block Casting Rear Wheel Drive Northstar Engine A380 GM Powertrain
Part Weight: 79.83 lbs. Alloy: Comments: Customer:
9-7
Casting Examples
Magnesium
Frame Novatel Expedite Modem AZ91D 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. Novatel Wireless Technologies, LTD
Customer:
Magnesium
Head Node Mountain Bike AZ91D 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. Cannondale
Customer:
Magnesium
Fishing Reel Ardent XS Fishing Reel AZ91D 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). Marsh Technologies, Inc.
Part Weight: 31.3 grams
Customer:
9-8
Casting Examples
Magnesium
Clutch Cover All Terrain Vehicle Clutch AZ91D 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. Polaris Industries, ATV Div.
Customer:
Magnesium
Camera Assembly Digital Camera AZ91D Originally designed as aluminum investment cast parts, the design complexity and required precision mandated a transition to magnesium die cast parts. Eastman Kodak
Customer:
Magnesium
Part Name: Application: Alloy: Comments: Customer:
Hand-Held Computer Housing Hand-Held Computer AZ91D Telxon Corporation
Part Weight: Over 0.5 lbs.
9-9
Casting Examples
Magnesium
Gear Case Housing Assembly Automatic Power Pruner AZ91D Magnesium was chosen for its 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. Echo
Customer:
Magnesium
Lock Housing SUV Tilt Steering Column AM60B 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. Visteon/Ford
Customer:
Magnesium
Fairing Support Bracket Buell 1125R Superbike AZ91D This bracket provides support for the motorcycles instrument cluster, windshield/cowling, direction signals and rearview mirror with increase copacity and a cost savings of aproximatly 26%. Buell Motercycle Co.
Customer:
9-10
Casting Examples
Magnesium
Seat Back and Cushion Luxury Car Seat Back and Cushion AM60B
Part Weight: Alloy: Comments: Customer:
Magnesium
Rear Frame Luxury Car AZ91D CTS/Venture Industries
Magnesium
Cross Car Beam for Instrument Panel General Motors Medium Duty Trucks AM60B 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. General Motors Truck
Customer:
9-11
Casting Examples
Zinc
Knot Marketing ZP5 This items shape has never been industrially manufactured and displays ingenious part and tooling design Nyrstar
Part Weight: 5.5 Grams
Customer:
Zinc
Bracket Electronics Enclosure Zamak No. 3 Converted from a machined aluminum alloy resulting in cost savings. The part is cast to net-shape thereby totally eliminating any machining.
Part Weight: 15.42 Grams
Customer:
Zinc
Faucet Handle Two Handle Lavatory Faucet Zamak No. 3 Major cost savings were achieved from tooling changes, which eliminated trimming, reduced polishing the parting line and machining operations. Delta Faucet Company
Part Weight: 119 Grams Alloy: Comments:
Customer:
9-12
Casting Examples
Zinc
Connector TERA Connector Zamak No. 3 Die casting offered superior EMI shielding and mechanical integrity at a favorable cost. Siemon Company
Part Weight: 0.4 oz.
Customer:
Zinc
Kitchen Faucet Hub Pull-Out Faucet Zamak No. 3 Delta Faucet Company
Part Weight:
Zinc
Fuel Fitting Dragon Fly Cook Stove Zamak No. 3 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. Mountain Safety Research
Customer:
9-13
Casting Examples
Zinc
Reverse Valve Casting Snap-On Tools Zamak No. 5 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. Vic Royal
Customer:
Zinc
Casket Arm Casket Zamak No. 3 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. Vic Royal
Customer:
Zinc
Display Frame Component Store Display Unit Zamak No. 3 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. CDC Marketing
Customer:
9-14
Casting Examples
Zinc
Outside Cover Power Lever Door Lock Zamak No. 3 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%). Mas-Hamilton Group
Customer:
Zinc
Front Plate L-20 Telecommunications Extension Shelf Za4Cu1 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. ALCATEL ITALIA S.p.A.
Part Weight: 3.53 oz. Alloy: Comments:
Customer:
Zinc
Connector Housing Fiber Optic Transceiver Zamak No. 2 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. Agilent Technologies
Customer:
9-15
Casting Examples
Zinc
Rearview Mirror Mount Windshild-to-mirror head transition housing 4.1 oz. Zamak No. 5 The part was designed around the mirror mounts humidity sensor for the smallest possible footprint. Gentex Corporation
Customer:
ZA (Zinc-Aluminum)
Tool Housing & Components Air-Powered Hand Tool ZA-8 and ZA-27 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. Snap-On
Part Weight:
Customer:
ZA (Zinc-Aluminum)
Transmission Shift Selector Tube Unit Passenger Car & Light Truck ZA-8 This single die casting replaced a four piece assembly and resulted in an estimated 50% cost savings
Part Weight: 1.1 lb. Alloy: Comments:
Customer:
9-16
NOTES
9-17
NOTES
9-18

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Casting Examples

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.35 lbs.

Part Weight: 0.48 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.85 lbs.

Part Weight: 1.4360 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 1.91 lbs. Alloy: Comments:

Part Weight: 8.2 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 9.2 lbs. Alloy: Comments:

Part Weight: 9.2 lbs.

Part Weight: 15.8 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 10.29 lbs Alloy: Comments:

Part Weight: 16.31 lbs.

Part Weight: 16.5 lbs. Alloy: Comments:

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 16.8 lbs.

Part Weight: 23.4 lbs. Alloy: Comments:

Part Weight: 79.83 lbs. Alloy: Comments: Customer:

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.01 lbs.

Part Weight: 0.22 lbs.

Part Weight: 31.3 grams

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.44 lbs.

Part Weight: 0.48 lbs.

Part Weight: Over 0.5 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.64 lbs.

Part Weight: 2.02 lbs.

Part Weight: 2.71 lbs.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: Alloy: Comments: Customer:

Part Weight: 7.51 lbs.

Part Weight: 21.5 lbs. Alloy: Comments:

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 5.5 Grams

Part Weight: 15.42 Grams

Part Weight: 119 Grams Alloy: Comments:

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 0.4 oz.

Part Weight: 0.5 oz.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 1.06 oz.

Part Weight: 3.5 oz.

Part Weight: 26.16 oz.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 3.0 lbs.

Part Weight: 3.53 oz. Alloy: Comments:

Part Weight: 0.19 oz.

NADCA Product Specification Standards for Die Castings / 2009

Part Weight: 1.1 lb. Alloy: Comments:

NADCA Product Specification Standards for Die Castings / 2009

NADCA Product Specification Standards for Die Castings / 2009

NADCA Product Specification Standards for Die Castings / 2009

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