Quality Tool, Zinc & Aluminum Die Casting - Advanced Technology

Technology advances have rapidly changed the field of High Pressure Die Casting and has been a key factor in the success and growth of Premier Tool & Die Cast. From concept ideas and partnering with research groups, to embracing and implementing proven new concepts, technology has become part of the Premier culture.

Computer Simulations

Using advanced computer simulations the die-casting process and die design can be evaluated. Any area identified as less than optimal can be changed in design before the actual building of the mold. These software tools have proved to target and suggest. 1.) Part geometry that would improve the castability of a part. 2.) Provide data to make changes in a die cooling design to reduce hot & cold spots creating a better balanced temperature zone in the mold. 3.) Compare metal delivery systems (gates & runners) improving how molten metal enters, fills and solidifies in the mold. These tools and more combine to play an important part on casting quality during production.

Fill Simulation

Start of fill shows direction of flow, air entrapment, and symmetry of flow between cavities.

Middle of cavity fill gives an indication of vectors of metal flow, potential cold shut and air entrapment.

Final fill shows cold areas, last areas to fill with metal and allows for evaluation of overflow placement. Color Indicates steel temperature for cooling system evaluation.

Solidification Simulation

Mold full of liquid metal.

Solidification begins. Color indicates part temperature.

As metal solidifies color disappears. In gates are now solidified,
intensification no longer effective.

Last areas to solidify are more prone to shrink porosity.

Distortion/Shrinkage Simulation

Simulations are now targeting how a part will shrink as it solidifies in the mold and after is has been removed. Variables such as part geometry, mass, cross sectional thickness, casting process, quench, etc. affect directional shrink and part distortion.

Die Coatings / Die Materials

X-Ray

Premier Tool & Die Cast continues to work in conjunction with NADCA and the Colorado School of Mines as a production based test site and with active participation with research committees. Primary areas of interest are die coatings, specialty tool steels and steel heat treatment. The goal is to prolong die life and reduce the occurrences of soldering during the normal life of a die. Improvements in this field are continually used and tested on production tooling, striving to delay the onset of tooling defects and increase the number of parts that can be produced from a mold.

Our X-Ray Fluoroscope is used for process verification and development along with trouble shooting casting problems. This unit allows real-time images while rotating parts and can generate paper or video images.

Coordinate Measuring Machine (CMM)

7 CMM’s give detailed dimensional information for prompt and accurate first article sample submissions. Our CMM’s are also being used for in process production checks. With the programmability and flexibility of the CMM’s, they are quickly replacing many of the expensive dedicated gages of the past.

Tensile/Compression Testing

Spectrometer

Compression and Tensile Testing up to 100 Kn

The Spectrometer analysis of the alloy chemistry is performed on a daily basis. A360, A380 and P387 (a tailored alloy with high compression properties) are the alloys used in production daily.

Value Added / Value Engineered

Premier’s engineers are able to work with customers to modify existing part designs or to design the complete part to customer specifications. Part models often do not have specific detail that is important to the die casting process. Draft, parting line development, ejector pin location, and constant wall thickness are part of the finished 3D model requirements. Reduction of part weight is sometimes possible by thinning walls or replacing thick sections with ribs. Lighter thinner wall parts reduce material cost and require less time to produce.

The part on the right shows the first generation part. The part on the left shows a redesign focusing on weight elimination.