Engineering & Design: Additional Specification Guidelines

Section Contents Frequently Asked Questions (FAQ) Introduction 1 Pressure Tightness 2 Fillets 3 Ribs and Corners 4 Ejector Pins, Pin Marks and Pin Flash 5 Metal Extension (Flash) Removal 6 Surface Finish, As-Cast 7 Die Cast Lettering and Ornamentation G-6-1-12 G-6-2-12 G-6-3-12 G-6-4-12 G-6-5-12 G-6-6-12 G-6-7-12 Guideline Guideline Guideline Guideline Guideline Guideline Guideline NADCA No. Format Page 6-2 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-10

SECTION

NADCA Product Specication Standards for Die Castings / 2012

6-1

Engineering & Design: Additional Specification Guidelines

Pressure-tightness specications for die castings, to assure containment of liquids or gases in use, require deviations from standard production and inspection practice. Extra steps, including special pressure-testing equipment and testing procedures, are usually needed.

Frequently Asked Questions (FAQ)

1)  How much ash can be expected to remain on a die casting after degating and trimming? See page 6-7, Metal Extension (Flash) Removal. 2)  If lettering is cast into the part, what are the options? See page 6-10, Die Cast Lettering. 3)  A re ejector pin marks required on the casting and will they have ash? See page6-6, Ejector Pins, Pin Marks and Pin Flash. 4)  W hat is a typical pressure tightness that die castings can withstand? See page 6-3, Pressure Testing. 5)  W hat is the best surface condition I can expect on die cast surfaces? See page 6-8, Typical As-Cast Surface Roughness Guide. 6)  W hy add ribs to the casting in-place of thick sections? See page 6-5, Ribs and Corners.

Introduction
The die casting specications discussed in this section relate to aspects of die casting design and production for which precise standards are dicult to set forth. As in previous Engineering sections, they replace the former ADCI/NADCA E Series. They include characteristics which are highly dependent on the design and shape of the particular part to be die cast, such as pressure tightness of the nished part; the proper design of llets, ribs and corners in a part; the consideration of ejector pin locations, pin marks and pin ash; casting ash and its removal; as-cast surface nish specications; and the casting of lettering, logos and ornamentation on the part surface. While specications will vary with the desired characteristic, certain guidelines have been established for die casting production under normal practice which can yield the most economic results. It is obvious that close consultation with the die caster prior to freezing design decisions is the wisest course to follow.

Pressure Tightness in Cast Parts

Assurance of pressure tight castings is highly dependent on the design conguration of the part. Consultation with the caster in the early design stages is essential where a specication for pressure tightness exists, in order to take advantage of basic product design, casting die design, and production processing factors. All of these factors are involved in insuring pressure tightness of the nal cast part. While most cast part designs can be cast pressure tight, specic castings may require impregnation to achieve required pressure tightness.

Special Notification Required

Specications for pressure tightness will require deviations from standard production and inspection practice. Special pressure testing equipment and testing procedures are usually needed. The requirement for pressure tightness should be made only where it is essential to the performance of the nished part. Where so specied, test methods and inspection procedures should be agreed upon in advance between the customer and the caster. Duplicate test xtures and test methods are recommended wherever possible. The discussion of Porosity and Pressure Tightness under Quality Assurance, Section 7 of this manual, should be reviewed.

6-2

NADCA Product Specication Standards for Die Castings / 2012

Engineering & Design: Additional Specification Guidelines

Guidelines for Pressure Tightness
Important considerations relating to the economical production of pressure-tight castings include the following guidelines:

NADCA G-6-1-12
GUIDELINES
Pressure-tightness specications for die castings, to assure containment of liquids or gases in use, require deviations from standard production and inspection practice. Extra steps, including special pressure-testing equipment and testing procedures, are usually needed.

1. Product Design and Die Design

Successful casting of pressure-tight castings require close conformance to the principles of good casting product design. a. Guidelines concerning llets, ribs and corners (G-6-2 and G-6-3), in this section, should be followed very carefully. b. Part wall sections should be of uniform thickness as much as possible. c. Holes and passages requiring pressure tightness should be cored to reduce porosity, as opposed to machined after casting. d. Ample draft should be provided in all cored holes and passages which are not to be machined. Cored holes which are to be machined should be given minimum draft (see Draft Tolerances pg. 4A-21). e. Heavy sections, as well as abrupt changes in sectional thickness, should be avoided. f. Special vacuum casting techniques may be required in addition to special steps in temperature control, the use of squeeze pins and other procedures to achieve nal part specications where the part design does not conform to good casting design guidelines.

2. Secondary Machining
The nature of the casting process is such that the outer surface of a casting is usually dense. Thus, thinner walls will be largely free of porosity, while thicker walls can be expected to contain some porosity within. Pressure-tight designs must set strict limitations on secondary machining. a. A minimum amount of machining stock should be removed, to avoid exposing porosity by cutting deeply into a casting (see Machining Stock Allowance Tolerances, pg. 4A-40). b. Large draft angles, which would require the removal of a large amount of stock from a surface to be machined, should be avoided, particularly where holes are cored. c. Machining both sides of the same section of a pressure-tight casting should be avoided. d. Where machining can expose porosity, impregnation may be required to insure pressure tightness. (See gure 7-5.)

3. Die Casting Alloy Selection

Certain alloys are best for producing pressure-tight castings. Refer to the Alloy Data sections for alloy comparisons of pressure-tightness characteristics to aid in the selection of the most favorable alloys.

4. Pressure Testing
Pressure-tightness testing for castings is generally specied in the range of 5 to 40 psi. Higher pressures will require extra special consideration by the caster and will be almost entirely a function of the part design. In the case of pressure-tight casting requirements, review inspection procedures in of Commercial Practices, Section 8, and Porosity Control on pg. 2-11.

NADCA Product Specication Standards for Die Castings / 2012

6-3

NADCA G-6-2-12
GUIDELINES
These recommendations regarding the design of llets, ribs and corners represent guidelines which will result in die casting at the most economic level under normal production practice. Sharp inside surface junctions, acute angle corner conditions and delicate, deep and closely spaced ribs should be specied only where and when necessary, since additional costs may be involved.

Engineering & Design: Additional Specification Guidelines

2 Fillets
Intersecting surfaces forming junctions are best joined with llets to avoid high stress concentrations in both the die castings and the die casting die. This will reduce die maintenance costs and increase the life of the die. In the sketches below, consideration has been given to the normal stresses on the die cast part in use and to the stresses induced in the die castings by the casting process itself, as well as to other manufacturing and die maintenance considerations.

Fillets in Die Cast Parts

Fillet Draft
Fillets projected in a direction normal (perpendicular) to the parting line require draft. The amount of draft is always governed by the draft of the intersecting surface, if a constant llet radius is maintained.

Shallow vs. Deep Die Casting Designs

These suggestions apply to llets on corners which are projected normal to the parting plane in die castings of moderate depth. Shallow die castings may have much smaller llets, while deep pockets and other inside corners should have larger llets.

Avoid Long, Sharp Corners

Long, sharply squared corners projecting in a direction normal to the parting plane may cause spalled edges on the die casting and should be avoided.
Recommended Fillet Designs and Allowances
WHERE T1 = THICKNESS OF THINNEST METAL AT JUNCTION WHERE T1 = T2 T1 R1 TEE JUNCTION T1 T2 R1 R1
POINT OF TANGENCY

Less Desirable
ANGULAR TRANSITION R1 Too Large R1 Approaching Zero R1 R1

T1

R2 0

Fig. 1 IF R 2 = R1 + T1; R1 = T1
WITHOUT LIMIT

Fig. 2 TEE JUNCTION / R1 = T1 TO 11 4 T1 T1 + T2 2 2(T1 + T2) Fig. 3 T2

Fig. 8 HEAVY MASS HERE NOT CONDUCIVE TO SOUND METAL.

Fig. 9 DIFFICULT TO MAINTAIN IN DIE.

Not Recommended
NO FILLET

IF R 2 = 0; + R1 = T1 TO 11 / 4 T1 WHERE T2 > T1 R1 T1 R1 T2

CORSS OR Y JUNCTION cross

ANGULAR TRANSITION INCREASES STRENGTH BUT COSTLY DIE WORK.

T1

R2 R2 Fig. 6 T1 R1

DEFLECTOR Fig. 10 Fig. 11 WEAK CASTING, DIFFICULT TO MAINTAIN IN DIE.

R2

Fig. 4 R1 = (T1 + T2) R 2 = 0 TO R1 + R 2

2 / 3

Fig. 5 = 90; ALL RADII EQUAL T1 = 45; R1 = 0.7 T1 R1 = 1.5 T1 = 30; R1 = 0.5 T1 R1 = 2.5 T1

Fig. 7 DEPRESSION PROMOTES DENSITY, ESPECIALLY UNDER CYLINDRICAL BOSSES, BUT ADDS TO DIE COST.

R1 Fig. 12 SHARP IRREGULAR EDGE-DIFFICULT TRIMMING

NO FILLETS

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

Fig. 12

6-4

NADCA Product Specication Standards for Die Castings / 2012

Engineering & Design: Additional Specification Guidelines

3 Ribs
Ribs are used to increase the stiness of, or add strength to, a die casting and to aid in making sound die cast parts. Ribs are sometimes misused and can be a detriment if working stresses are concentrated by their use or if high stresses are created at the edges of the ribs by their design.

NADCA G-6-3-12
GUIDELINES
These recommendations regarding the design of llets, ribs and corners represent guidelines which will result in die casting at the most economic level under normal production practice. Sharp inside surface junctions, acute angle corner conditions and delicate, deep and closely spaced ribs should be specied only where and when necessary, since additional costs may be involved.

Ribs and Corners in Die Cast Parts

External Corners
Sharply squared external corners may be used in some locations if die construction permits. This type of corner is mandatory at parting line locations and die block intersections. Elsewhere, corners of die castings should have radii to prevent early die failure, to reduce the probability of nicking the edge of the die casting in handling and assembly, and to minimize material handling hazards for personnel.

Recommended Rib Designs and Allowances

h T1 BLEND h T1 Fig. 2 WHERE h > T1 CORE OUT UNDERNEATH TO AVOID UNDESIRABLE HEAVY MASS OF METAL. T1 Fig. 3 BLENDING AS SHOWN MAY BE DESIRABLE.

Not Recommended
R SHARP CORNERS SMALL RADII.

Fig.8

Fig. 1 h = T1

NO RIBBING BOSS EXTENSIONS LESS DESIRABLE FOR CASTABILITY

BLEND RIBS INSIDE GOOD DISTRIBUTION OF METAL FOR ALL PURPOSES. Fig. 4

Fig.9

RIB EXTERNAL RIBS MAY CAUSE POOR DISTRIBUTION OF STRESS

Fig.10

Fig. 7 Fig. 5 GOOD DISTRIBUTION OF STRESSES Fig. 6 RIB FROM FLANGE TO BOSS GENEROUS DRAFT AND FILLETS NOTE ANGULAR TRANSITION.

SHARP CORNERS SMALL RADII LITTLE DRAFT

Fig.11

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

NADCA Product Specication Standards for Die Castings / 2012

6-5

NADCA G-6-4-12
GUIDELINES
The guidelines presented here for the location of ejector pins, pin mark tolerances and procedures regarding pin ash represent standard die casting production practice at the most economic level. Disregarding these guidelines should be done only when and where essential to the product design, since additional cost may be involved.

Engineering & Design: Additional Specification Guidelines

4 Ejector Pins, Pin Marks and Pin Flash
Ejector Pin Operation

Ejector Pin Marks

Moveable ejector pins must be used to eject a die casting from the die casting die and will result in a residual ejector pin mark on the die cast part. In addition to automatically pushing the casting from the die after part solidication, ejector pins also serve to keep the casting from bending. The sequential illustrations at right demonstrate the action of the ejector pins in a die casting cycle.

Location Of Ejector Pins

Ejector pin locations should be at the option of the die caster, subject to the customers agreement. Where considerations of cast surface cosmetics are important, ejector pin locations should always be discussed in advance of die design. The number, size and location of ejector pins and bosses required will vary with the size and complexity of the die casting, as well as with other factors.

Figure A

Acceptable Ejector Pin Marks

Ejector pin marks on most die castings may be raised or depressed .015 (.381 mm). Raised ejector pin marks are preferred for optimum production. Larger castings may require additional ejector pin tolerances for proper casting ejection.

Figure B

Ejector Pin Flash

Ejector pin marks are surrounded by a ash of metal. Normally, ejector pin ash will not be removed, unless it is objectionable to the end use of the part. Alternatively, ejector pin ash may be specied as crushed or attened. In the case of either nonremoval or crushing/attening, ash may ake o in use. Complete removal of ejector pin marks and ash by machining or hand scraping operations should be specied only when requirements justify the added expense. With each die casting cycle, the die opens and the ejector plate in the ejector half of the die (Fig. A) automatically moves all ejector pins forward (Fig. B), releasing the casting from the die. Then, the die casting is removed from the die manually or mechanically.

Figure C

6-6

NADCA Product Specication Standards for Die Castings / 2012

Engineering & Design: Additional Specification Guidelines

5 Metal Extension (Flash) Removal

NADCA G-6-5-12
GUIDELINES
The guidelines for removal of die casting metal extension (ash) presented here represent normal production practice at the most economic level. Precision ash trimming, closer than standard commercial trimming, or the complete removal of all extension involves additional operations and should be specied only when requirements justify the additional cost.

Metal Extension (Flash) Formation and Location

An extension of metal is formed on die castings at the parting line of the two die halves and where moving die components (also called moving die parts) operate (see Figure 6-1). A seam of metal extension may also be formed where separate die parts cast a part feature. Residual metal extension is also formed by the normal operation of ejector pins and is discussed on the previous page.

Simplifying Extension (Flash) Removal

Necessary casting metal extension removal costs can be reduced by consideration, in the design stages, of the amount of metal extension to be removed and the removal method to be employed. Early consultation with the die caster can often result in production economies in the treatment of metal extension removal.

Guidelines to Extent of Removal

The table below provides a guide to the types of die casting metal extension (ash) which occurs in typical die castings and the amount of metal extension material which remains after (1) degating (removal of any gates and runners from the casting), and (2) commercial trimming of die casting metal extension. Note that in some instances, where special surface nish characteristics are not involved, the most economic method of degating and metal extension (ash) removal may include a tumbling or vibratory deburring operation.
Guide to Nominal Metal Remaining by Type of Extension Type of Metal Extension and Nominal Amount Remaining After Degating and Trimming Operation Description After Degating
Nominal Flash Remaining

Thick Gates & Overows > 0.12 (3.0 mm) Rough within 0.12 (3.0 mm)

Thin Gates & Overows < 0.12 (3.0 mm) Rough within 0.12 (3.0 mm)

Parting Line and Seam Line Metal Extension Excess Only Broken O

Metal Extension in Cored Holes Not Removed Removed within 0.010 (0.25 mm)

Sharp Corners Not Removed Not Removed

After Commercial Trimming*

Nominal Extension Emaining

Within 0.06 (1.59 mm)

Within 0.03 (0.8 mm)

Within 0.015 (0.38 mm)

* Commercially trimmed does not include additional operations to remove loose material. For very heavy gates and overflows, consult your die caster.

Figure 6-1: Examples of complex parting lines that can make ash extension removal more dicult.

NADCA Product Specication Standards for Die Castings / 2012

6-7

NADCA G-6-6-12
GUIDELINES
The as-cast external surface nish classications shown here illustrate variations in production practice. Surface nish requirements should be specied for production at the most economic level. Generally, extra steps in die design, die construction and casting production are required for the more exacting nishes, and additional cost may be involved. Selection of the lowest classication number, commensurate with the die cast part application, will yield the lowest cost.

Engineering & Design: Additional Specification Guidelines

6 Surface Finish, As-Cast

General Guidelines for As Cast Surface Finish on Die Cast Parts

The specication of external surface nish requirements is desirable for selected die casting applications and, in the case of some decorative parts, essential. The purpose of the guidelines presented here is to classify as-cast surface nish for die castings into a series of grades so that the type of as-cast nish required may be addressed and dened in advance of die design. These guidelines should be used for general type classication only, with nal surface nish quality requirements specically agreed upon between the die caster and the customer. The rst four classes listed relate to cosmetic surfaces. Class ve relates to selected surface areas where specied surface nish limitations are required.
As-Cast Surface Finish Classications and Final Finish or End Use Class As-Cast Finish No cosmetic requirements. Surface imperfections (cold shut, rubs, surface porosity, lubricant build-up, etc.) are acceptable Final Finish or End Use Used as-cast or with protective coatings; Anodize (non-decorative) Chromate (yellow, clear) Decorative Coatings: Lacquers Enamels Plating (Al) Chemical Finish Polished Finish

1 2 3
NOTE: As-cast surface nish classication does not apply to machined surfaces. Finished machined surface requirements shall be as agreed upon between the die caster and customer and separately identied on the engineering part drawing.

Utility Grade

Functional Grade

Surface imperfections (cold shut, rubs, surface porosity, etc.), that can be removed by spot polishing or can be covered by heavy paint, are acceptable.

Slight surface imperfections that can Commercial be removed by agreed upon means are acceptable. Grade

4 5

Consumer Grade Superior Grade

No objectionable surface imperfecSpecial Decorative Parts tions. Where surface waviness (atness), noted by light reection, is a reason for rejection special agreement should be reached with the die caster. Surface nish, applicable to limited areas of the casting and dependent on alloy selected, to have a maximum value in micro inches as specied on print.

Structural Parts (high stress areas) Plating (Zn) Electrostatic Painting Transparent Paints

O-Ring Seats or Gasket Areas

Typical As-Cast Surface Roughness Guide Typical Surface Roughness (m-inches) Alloy Family / Alloy Aluminum, ZA-12, ZA-27 Magnesium Zinc, ZA-8 Expected in a New Die 63 or better 63 or better 32 or better Over the Life of a Die 63 should be maintainable 63 should be maintainable 100-125

Notes: 1. Part design, gate location, draft, ow lines, die surface treatments and other factors can impact surface roughness. 2. Roughness values for Over the Life of a Die do not include heat checking in the die. 3. Die lubricants utilized for special applications may impact surface roughness and the values in the table may not be achievable.

6-8

NADCA Product Specication Standards for Die Castings / 2012

Engineering & Design: Additional Specification Guidelines

Coatings for Castings
Coating Pretreatments A lodine 5200 Chromate (Class 1A & 3) I ron Phosphate N H 35 Urethane Primers E poxy Z inc Rich Applicable Material A l, Mg A l, Zn A l, Mg, Zn Mg A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn Al A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l*, Mg A l, Mg A l, Mg, Zn A l, Mg, Zn A l, Mg, Zn A l, Zn A l, Zn A l, Zn A l, Zn A l, Zn A l, Mg, Zn A l, Mg, Zn Advantages 1, 2, 3 1, 2, 3, 4 1, 3 1, 2, 3 1, 3, 5 1, 2, 3, 6 1, 2, 3, 6 1, 2, 3, 5 1, 2, 3, 6 1, 2, 3, 5, 6 Price Low Low Low Low Medium Medium Medium Low Low High
Legend for Advantages:

1 Corrosion protection 2 Chemical resistance 3 Adhesion enhancement 5 Flexibility

4 Conductivity 6 Hardness/ wear resistance/ durability/ mar resistance 7 UV resistance 8 Decorative nish

Z inc Chromate E -Coat

Vinyl Acid Wash Urethane E poxy A crylic

Liquid Topcoats

1, 3, 5, 6, 7 1, 2, 3, 6 1, 3, 5, 6, 7

Medium Medium Medium Medium High Low Low

*A  nodizing of aluminum is contingent upon the specic alloy and may not yield an aesthetically pleasing surface.

Waterbase Polyester T GIC

Operations PoWder coats

F luropons/ Architect

1, 2, 3, 5, 6, 7 1, 2, 3, 5, 6, 7 3, 5 1, 2, 3, 5, 7 3 , 5, 7 1, 2, 3 1, 2, 3 1, 2, 3, 5, 6, 7 1, 2, 3, 6, 7 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 4, 6, 8 1, 2, 3, 4, 6, 8 1, 2, 3, 4, 6, 8

Urethane E poxy Hybrid

Medium Medium Medium Low Medium High High High High High Very High Very High High High High

Anodic Films

A nodize H ardcoat - Hard Anodizing C opper C opper/Nickel Brass Z inc

Electroplating ElectRoless Plating

Cu/Ni/Chrome Bronze S ilver G old

E lectroless Nickel E lectroless Copper

For more details contact a viable coating source. Note: Not all die castings readily accept electro-coatings. Vacuum plating films such as PVD and CVD coatings, mechanical plating such as Zinc/Tin, and thermal spray coatings may also be applied. Consult with the the applicable coating suppliers.

NADCA Product Specication Standards for Die Castings / 2012

6-9

NADCA G-6-7-12
GUIDELINES
The guidelines presented here for incorporating logotypes, lettering and ornamentation in a die cast part represent normal production practices at the most economic level. Fine detail in lettering and art styles can be achieved but may involve additional costs.

Engineering & Design: Additional Specification Guidelines

7 Die Cast Lettering and Ornamentation
Lettering, medallions, logotypes, trademarks and a range of identication symbols may be reproduced on the surfaces of die cast parts. Such as-cast ornamentation may be raised or depressed, but note that raised lettering will result in lower die construction costs and reduced die maintenance over the life of the die. Raised lettering on a depressed panel can be an economical substitute for depressed letters, as shown in the illustration below.

Cast-in Lettering/Ornamentation Guidelines

In addition to the avoidance of depressed lettering or symbols in the casting surface, the following guidelines will achieve the most satisfactory results. The terms used refer to the illustrations below. 1. The Line Thickness (or face) of any letter to be clearly cast should be 0.010 in. (0.254 mm) or greater. 2. The Height (or raised dimension) of a cast letter or symbol should be equal to or less than the line thickness. 3. The Draft Angle should be greater than 10. 4. Letters or symbols containing ne serifs or delicate lines cannot be expected to die cast cleanly.

Sample Letter or Symbol

Three Alternative Die Cast Effects

LINE (OR FACE)

SIZE

DRAFT ANGLE

DRAFT ANGLE HEIGHT RAISED Fig. 1a DEPRESSED NOT RECCOMENDED Fig. 2a

DRAFT ANGLE HEIGHT RAISED IN DEPRESSED PANEL Fig. 2a

Fig. 1b

Fig. 2b

Fig. 2b

6-10

NADCA Product Specication Standards for Die Castings / 2012