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Forging Raises the Bar on Magnesium Die Casting
With magnesium emerging as "the new aluminum" due to its exceptional light weight, hot chamber magnesium die casting is gaining popularity in the manufacturing world. The process produces magnesium parts with precise dimensions in a variety of configurations, but it can be demanding on die casting machines, particularly on the gooseneck that delivers the molten magnesium to the die. Sloan Industries, Inc., a Wood Dale, IL-based precision machine shop who supplies wear parts to the magnesium die casting industry, has discovered that using forged, rather than the more commonly cast goosenecks, will yield better machine performance and part quality. Together with Scot Forge of Spring Grove, IL, the company has begun supplying forged goosenecks to the industry-and they are able to do so at competitive costs, due to creative engineering.Get more news about Magnesium Alloy Casting,you can vist our website!
"It was critical for us to supply an improved product to support our growing customer base in the magnesium die casting industry," says Henry Slowinski, the company's president. He notes, "They're making magnesium parts for everything from laptops to supermarket scanners." Magnesium is becoming the lightweight manufacturing material of choice in high tech, space, auto and other industries because of its excellent strength-to-weight ratio, good dimensional stability, and recyclability. "It isn't as brittle as aluminum," Slowinski adds.
The hot chamber magnesium die casting process uses a gooseneck and piston to inject molten magnesium into a die. The gooseneck is submerged into molten magnesium, and through the side fill holes, the gooseneck cavity is filled with molten magnesium. The piston then forces the molten metal down from the top, delivering the metal through the gooseneck's vertical delivery hole, nozzle and into the die without exposure to the environment. After the metal turns solid inside the die cavity, the die opens, the part is ejected and at the same time the piston retracts to its initial position above the fill holes. Then again, the die is closed, and the gooseneck is filled with molten metal and ready for the next injection.
Improving the Goosenecks
Sloan Industries supplies goosenecks to various customers in sizes ranging from 80 to 528 tons. Sloan machines the goosenecks with precision quality. All of the goosenecks must be able to withstand temperatures of 1300 degrees, and must hold up against magnesium, which is highly abrasive. Until recently, the goosenecks that Sloan provided were made from sand castings. But imperfections in the cast goosenecks were causing cracking, porosity, and machining problems.
"Specifications called for DIN 1.2888 cast steel, which would hold up under the chemical and high temperature demands, but it was expensive and difficult to cast," says company vice president Adam Niedospial. "The inconsistency of cast goosenecks, unexpected porosity and shrink pockets caused difficulties and delays in machining."
He continues, "As many as 40% of the castings had to be scrapped before we supplied our customers. This was costly for us, and affected our on-time delivery."
Sloan looked for an alternative to castings, and considered switching to making the goosenecks from solid bar. This method would require excessive material, extensive machining, and as a result, the cost would be non-competitive.
A Proactive Partnership
Providing a high-quality, cost-efficient forging solution was right up Scot Forge's alley. Scot Forge offers a "Proactive Partnership" program in which they work with machine shops and metal part buyers to optimize part quality, while minimizing waste and reducing costs. The program, led by an experienced metallurgist, was designed to discover ways for producing high quality parts less expensively using the forging process. It identifies and eliminates unnecessary processing while improving part strength, often by combining multiple components into one higher-strength part.
In this case, the gooseneck dimensions called for a spindle with a square head. If Scot Forge could make this shape, Slowinski thought, Sloan could then machine the gooseneck at a much more cost-effective price than from solid bar.
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