M^'

^C(t^

HANDBOOK. ON
DIE CASTINGS

fPRECISION
I

Gmii^ complete
miormation about

and casKn^
processes, metak
dies

methods of jfabri^^
at/on, fihishiW
etc -with useful
tahles.

Q"'

\i-^-ij^uii.\h\

Index Pages 94-95

Copyright, 1919

PRECISION CASTINGS

COMPANY

Syracuse, N. Y.

HAND-BOOK
ON

DIE-CASTINGS
CONTAINING

USEFUL INFORMATION FOR

MANUFACTURERS AND
ENGINEERS
CONCERNING

METALS, DESIGN, PROCESSES,

METHODS OF

FINISHING,
FABRICATING, ETC.,

WITH TABLES

By

EDGAR

N.

DOLLIN

Published by

PRECISION CASTINGS CO., INC.

SYRACUSE,
FAYETTEVILLE.

N. Y.

FACTORIES:
N. Y. and PONTIAC. MICH.

^^1\"fc'\

Roaring forge and reddening

Rhythmic

May

glozv.

siving of ha?nnier bloiv.

thy heartbeats never

more

Pulsate to the songs of war.

Glorious deeds of mighty meyi

Turn your

strength to peace again.

Muscle and braivn and gallantry now

Turn

to the factory

From

sea to sea,

turn to the ploiv.

throughout the land.

From northmost

lakes to the

Rio Grande,

Assemble your hosts and gather your might

Just as you did

when you fought

for your right.

Up and

to

Masters

of markets, princes of trade

work! Lead

Carry Old Glory

Fairly

and

justly

the crusade.

to the ports of the

and

FEB-.8

World

pro\}dly unfurled.

19!9"-^'^'*
J

Introduction
The

publication of this book

is

prompted by

a desire to give users of die-

castings and those interested in the art, complete information on the subject of
die-castings

We

and relative

topics, as there

is

available literature on the subject.

little

hope that the information herein given will bring about better co-opera-

and understanding between users and producers, and will enable users

tion

greater advantage of the

duction

made

The

many economies and improvements

any one man or organization.

by

many men and many

work

in

to take

product and pro-

possible by the die-casting process.

present development and wide use of die-castings

to

their

in

is

not to be credited

It is the result of contributions to the art

organizations almost

the United States.

all of

Die-casting

w^hom,

it

may

made

be noted, did

today essentially an American

is

industry.

Die-casting machines for making type, which were the forerunners of the
modern die-casting machines, were built in this country over seventy years ago.
The modern industry is about thirty years old and came with the advent of quantity

production of mechanical devices and machines.

The

Precision Castings Co., Inc., whose

ized in 1916 to take over the E. B.

work

is

VanWagner Mfg.

herein described,

the Precision Die Castings Co., organized in 1910.

years been widely and favorably

service.

The

range of work

known

was organ-

Co., organized in 1907, and

These companies have

for

for the high charactei of their product

and

combination has produced an organization doing an unusually wide

in large

volume without departing

in

any respect from the highest

and most exacting standards.

During the war our

with few exceptions.

entire facilities

have been devoted to government work,

We have made over one hundred

Precision Castings Co., Pontiac Plant.

different parts for motors,

Jl'ater

pump

impeller,

aluminum.

bombs,

Of

shells,

Combustion
motor zvater pump,

If'ater

zinc alloy.

tin

grenades, aeroplanes, trench mortars, guns,

one part for hand grenades alone,

we

pump

impeller,
alloy.

etc., in

large quantities.

delivered over 25,000,000 in less than

ten months.

To

be a die-casting, the part must be cast from fluid metal forced imder pres-

sure other than gravity into a metallic mold, sufficiently below the temperature of
the fluid metal to chill
tallic dies

Parts poured

it.

by gravity only, or formed up

non-metallic molds, or poured in me-

in

in dies

under pressure from

semi-fluid state, are not properly referred to as die-castings

a plastic or

and lack the accuracy

and range of design made possible by the die-casting process.

So

far,

metals successfully die-cast on a commercial scale are the alloys of zinc,

and aluminum fusing below about 1300 F.

the only
tin,

lead

Brass and bronze die-castings have

been offered to the trade at various times by several concerns, some of which have
discontinued business because they were unable to apply their process to general

commercial requirements, and others have been able

parts in limited quantities.

It

is

production on a commercial scale

become apparent

The

in the

is

to

produce only a few simple

not so difficult to die-cast a few samples, but

a different matter.

The

reasons for this will

following pages.

inherent limitations of the die-casting process in

are such that only certain adaptable metals

may

its

be used, and

present development

when

the particular

strength and qualities of steels and bronzes are required, die-castings cannot be
substituted for parts

1 he
there

is

not the

metal a factor.
as die-castings,

The

made

of those metals.

more accurate than punching or drawing sheet metals, because

same w^ear on the dies, nor is the spring and distortion of drawn

process

is

Forgings or parts pressed from plastic metal are not as accurate

and cannot be produced

following

list,

showing some

in as

wide

a range of design.

of the parts

castings are used, will give an idea of the extent to

applied in

modern production.

and devices for which

die-

which the process has been

Adding Machines

Motorcycles
Meters of all kinds
Military Equipment and Devices

Automatic Controlling Devices

Automobile Accessories and Parts

Armature Parts

Milking Machine Parts

Numbering Machines

Ammeter Housings and

Plates
Automatic Devices (small)

Novelties

Ammunition
Air Pumps

Office

Appliances

Organs

Atomizers
Aeroplane Parts
Bearings (plain)
Brush Holders for Electric Motors

Optical Appliances
Pencil Sharpeners

Phonographs

Cameras
Cash Registers

Pianos
Piano Players
Prepayment Devices
Printing Presses and Machines

Carburetors

Pulleys

Cigarette Machines
Clocks
Check Protectors

Plumbing Fixtures and Supplies

Rubber Molds

Brackets of various kinds

Switches (electric)
Switch Keys
Safety Razors
Starting-, Lighting and

Counting Machines

Cup Dispensers
Dental Appliances
Door Checks
Disinfecting and Sanitary Devices

for Combustion

Ignition

Sealing Machines

Electric

Horns and Signals

Envelope Machines
Engine Governors

Speedometers
Stamp AfHxers

Fire Extinguishers
Fare Boxes and Registers
Gears (small)

Soap Dispensers
Soda Fountain Fittings, Pumps,
Telephone Apparatus

Gas Engines
Hinges

Time

Storage Batteries

Instruments of various kinds

Knobs and Handles

Lamps

of various kinds
Loose Leaf Book Binding Parts

Magnetos

Moving Picture Machines

Motor Housings (small electric)
Marking Machines

ttn

.001".

Weighing
\^'^ater

alloy.

Note

the design reduces assembling! to a minimum.

hon.v

Clocks

Typewriters
Tabulating Machines
Table and Kitchen Ware
Thermostatic Devices
Tractor Accessories and Parts
Vacuum Cleaners
Vending Machines
Vibrators and Massage Devices

Hardware

Speedometer frame
Dimensions held to

Systems

Motors

Scales

and Oil Pumps

Etc.

Vending madiine,
zinc alloy.

10

Advantages of Using Die-Castings

I.

There
not

full}'

data

is

are

numerous advantages

many

of

which are

In manj' cases they present manufacturing advantages peculiar

available.

to the job in hand,

Much

in the use of die-castings,

appreciated until the castings are used for a given period and comparative

which

it

not possible to point out in a general summary.

is

depends on the character of the workmanship, ?naterial and service fur-

nished.

Die-castings which do not measure up to high commercial standards in these

three particulars frequently cause troubles and delays which destroy the \tvy

advantages which the process so admirably has over most others.

It

cannot be too

strongly emphasized that comparative prices of die-castings offered from competing sources should not be decisive in the placing of orders, although

On

follows that the lowest bidder offers the poorest material.

it

by no means

the contrarv

it

frequently happens that the best die-castings are furnished by the lowest bidder

because of his greater

lower

in cost

and experience which enable him

skill

and yet more thorough and

Accuracy and

^^^

^^ ^^^<^

,^,

L'T

Inter-Changeablllty

to

employ methods

effective in their results.

degree and range of accuracy which

is

may

covered fully in a separate chapter

uder that heading

(p.

51).

it

may

be said

here, that the elimination of error by avoiding

the

"human

any other

variable"

process.

is

The

accomplished
die

is

in die-castings to a greater

extent than by

virtually a gauge and the size of the castings

no way dependent upon the will or discretion of the operator.

Consequently

is

in

die-

which offers well understood advantages in manufacmaking replacements for broken or worn parts.

castings are interchangeable,

ture and assembly and in

Finish and Appearance

die-casting, unlike a sand casting, h^s a

perfect finish over

is

smooth and clean-cut.

The

the process used in manufacture, and

its

which

entire surface,

upon
upon the care and attention given the work.

excellence of the finish

is

largely dependent

The

highly developed and improved machines used by us make

which has never been attained by other methods.

possible a standard

Die-castings have a solid, substantial appearance, which makes them more

suitable for high class machines
in

many

cases, a

and devices than sheet metal

parts,

which have,

cheap or "tin can" appearance.

Almost any shape may be

cast,

frequently permitting a certain beauty or

grace in outline which would be impractical or prohibitive in cost by other

manu-

facturing methods.

RanP'e of DesiP'n ^

wider range of design

and commercial
by any other single means.

made
11

of die-castings, in

Many

whole or

devices are

in part,

is

brought within practical

limits by the die-casting process, than

now

designed so that they

may

be

and could not be commercially produced

other method.

b}^ an}-

great

many

devices

which could not be produced before

means

the advent of die-castings, have been resurrected and marketed by

of the

process.
It

is

not possible to convey by any general statements the range of shapes and

may

designs which

Each

limit.

case,

be die-cast, as the range of possible design

if it

die-casting engineer to determine

question

is

answered

changes which,

With
and

num

if

in the

whether or not the design

usable, will

overcome the

about 15 pounds

The

allovs.

size

seldom exceeds 24" over

is

rigidity

is

If the

practical.

always suggest

it

about 10 pounds

and about

in the zinc

pounds

alumi-

in

frequently happens that two or more

which must be produced sepa-

and assembled by other processes, may be combined

result

is

possible,

all.

parts

The

almost without

difficulties presented.

in the lead alloys,

Reduction of Assembling
rately

when

negative our engineers,

exceptions, the practical limit in weight

tin alloys,

is

presents any difficulty, must be passed on by an experienced

in a single die-casting.

greater accuracy, lower cost, better appearance, and generally greater

and strength, with no opportimity for the separate parts

to get out of line

or adjustment.

When
making

work

of assembling

is

much

the parts lock into each other in such a

adjustment and can readily be located

in

manner

We

This

is

be

done by

that they cannot lose their

in the other, or keys

tongued grooves, square holes, inter-locking lugs,

the uniformity

simplified.

the proper position; for this purpose

dowel pins on one part and corresponding holes

pensive.

may

assembling cannot be avoided for individual pieces, the parts

so designed that the

etc.,

may

and keyways,

be cast.

Of

course,

and accuracy of die-castings alone make assembling easy and inexhave been advised frequently by customers that the accuracy and

made

possible a reduction in their piecework

finish of

"Precision" castings has

rates, as

well as permitting other economies necessarily incident to higher and

more dependable production.

Die-castings as a general rule cannot be

Ouick
Delivery
'^
but they are

made

faster

than plain punchings or simple screw machine parts,

less liable to delays in

production caused by lack of sheet metal of

suitable kind or the needed sizes or shapes of rods or bars used on the screw

But

chines.

die-castings can always be produced

can be sand cast and machined.

high production.

On

much

ma-

faster than similar parts

Precision machines are capable of exceedingly

long runs an average of over 300 operations of the dies per

hour has been registered.

As
cesses

a rule less labor

would require

surer, because the die

is

required to produce a die-casting than any other pro-

for the
is

same part

consequently production

is

quicker and

virtually a positive automatic machine not subject to the

errors of machine work.

We

have not yet met with a case

in

which our daily production was below

12

the daily capacity of our customer to use the parts, excepting of course Govern-

ment orders placed during

When

the war.

made,

dies are once

deliveries,

when

a few days after receipt of order, dependent

removing the gates and

fins

from the

Intricate parts requiring a great deal of

The

of

in
in

when

suitable, usually presents a

but they are not always used for that reason alone.

cost advantage,

large saving.

commence
work involved

usually

castings.

^^^ things considered, a die-casting,

C^OSt

may

needed,

upon the amount

machining and finishing usually present a

die-casting process, generally speaking,

may

sand casting, and for that reason sand castings that

is

more expensive than

be used without machin-

ing or finishing operations cannot be die-cast to advantage.

No

idea of the cost of particular parts can be given, as this depends on the

weight, design, and quantity ordered, as well as on the die equipment; quotations

should be secured

each case.

in

In considering the cost of dies

investment usually needed

it

must not be forgotten that they

in other processes for patterns, jigs, fixtures

offset the

and

special

Furthermore, dies are not subject to the w^ear and deterioration of other

tools.
tools, as

they are kept by us in perfect condition without charge.

MachininP"

A.clva.nta.P"CS

^^ '^

frequently advisable to do machine

work

on die-castings when the machining operations are inexpensive

expensive.

This

Is

and the work of die-casting

thereby

is

made

simpler and

less

true of Inside threads in most cases, and sometimes of Inside

When

grooves, under-cut slots, etc.

machine work

is

done

it is

simpler and cheaper

than the same work done on sand castings, due to the uniformity of the die-castings,

and the ease with which they may be located

and

in jigs

reamed or surfaces ground or machined

holes are to be

a lighter cut taken,

due

to the

less

and

fixtures.

When

stock need be allowed

accuracy of the castings.

Manufacturing Advantages

^^^

^^^

manufacturing

advantages

cannot be enumerated because

many

are subject to the facilities of the manufacturer using them, and depend on the

particular or peculiar problems involved in each case.

user of die-castings reduces and frequently eliminates labor troubles, he

avoids idle tool equipment, as

is

is

the case

not up to their yearly capacity.

loss

on equipment.

less light, less

There

He

To

when

the

work

required of certain tools

the same extent he has no depreciation or

requires less capital for plant, he uses less factory space,

power, or releases them for other purposes.

are

many hidden

leaks and undiscovered losses in the average factory

which run

for long periods, resulting in

cost of the

work

is.

some uncertainty

as to

what

the actual

Die-castings, on the other hand, enable a manufacturer to

secure his finished part ready for assembly at a definite, fixed, and dependable cost.
13

Envelope sealing machine,

Zinc and lead alloys.

14

Cost and Suggestions to Purchasers

II.

Die-castings are sold at a price per piece or set of pieces, and the dies are the

The

subject of a separate charge.

following factors of cost are considered

in

preparing estimates
1.

Weight.

2.

Kind

of metal used.
Quantity ordered in one run or setting of the
Total quantity ordered.
Casting production per hour.
Cleaning operations required.

3.

4.
5.
6.

dies.

Die-castings, as pointed out before, are not always cheaper than the

parts produced by other processes, as the production of casting machines

same

not high

is

compared with screw machines or presses. A casting machine to be run efficiently,

requires two operators and represents a high daily maintenance cost for power,
fuel

and metal

It

losses.

is

therefore principally the labor cost of non-automatic

manufacturing operations that

work

chine

reduced by the use of die-castings, such as ma-

is

any kind, engraving,

of

grinding, spinning, bending,

fitting,

filing,

soldering, assembling, etc.

Setting the dies and getting them started

After the dies are started

and get up

it

takes

tity proposition,

hand

in

New

to a high average production.

For

be broken in and "seasoned".

slow and troublesome work.

is

some time before the men are familiar with them

dies require a certain time to

these reasons, the process

small quantities the cost

duction by other processes.

is

Generally a thousand

Small and simple parts should be ordered

iron

and

cost, the

consequence

expense will be

when
less

is

the

The

gates

parting line of the

the die.

a part

may

be

must be removed and

is

in

lot,

but very

smaller quantities.

all

made

more expensive than

steel or

of these metals at small labor

than that of die-castings.

die, in holes

This w^ork

but on the other

minimum

Cleaning or trimming die-castings after they are made

of cost.

in larger lots.

white metals used for die-casting are

in

essentially a quan-

sometimes much greater than for the same pro-

heavy and expensive parts are sometimes made to advantage

The

is

permitting very low production cost in long runs

also the fins

and around the parting

sometimes

difficult

is

an important item

which appear around the

line of all

and tedious and

if

moving

parts in

carelessly or cheaply

done will detract from the appearance and accuracy of the castings or

spoil

them

entirely.

made

In large quantities, special jigs and fixtures or cleaning tools can be

reduce this

cost,

but

it

nevertheless frequently amounts to

given to this branch of the

labor.

In the Precision shops special attention

is

work.

We give

We

for operations

which require care or

do not employ cheap labor

The equipment

used in our cleaning

is

Comparatively light and simple

to justify the die cost,
15

skill.

modern and accurate, many tools having been specially designed and
by us for work to which standard equipment is not so well adapted.

department
built

each operation close inspection.

to

more than the casting

may

be

made

parts,
in

when used

in quantities large

multiple dies running as high as

enough

fifty

im-

Aluminum

steering

column sectors and levers,

spark and throttle control gears,

szvitcli keys, etc.

pressions, according to the piece.

power

of the machines

and the

The

Precision process, due to the pressure and

die construction employed,

permits the use of

unusually large dies and the casting of a wide range of combinations

We

in

one mold.

sometimes make an entire machine consisting of seven or eight parts

in

single combination die, thereby greatly reducing die cost as well as casting cost,
since a combination die of eight parts

parts or four dies of

two parts each.

should always be ordered

would not

When

in sets as it is

cost as

much

as

two

die3 of four

combination dies are made, the parts

not practical to

make

castings out of a por-

tion of a die only.

Except

may

in

very plain cases, the only

be die-cast to advantage

is

to

submit

way
it

to

determine whether or not

a part

for estimate.
16

In comparing estimates

and

it

must not be forgotten that you are buying service

The workmanship and service of

and not a stock commodity.

skilled labor

no two die-casting companies are

engineers, or architects

The work
character.

It

alike, just as the service of

no two doctors, or

alike.

of the Precision Castings Co., Inc., has

its

own

individuality and

men

turned out by an organization of the most skilled

is

Every

industry.

is

detail has been

worked out

to

its

Precision product a finished product in every sense of the word.

tor has assistants in every

department

who

Our

in the

making the

logical conclusion,

chief inspec-

follow the work from beginning to end,

preventing factory losses and delays and avoiding the production and shipment of
defective parts.

We
order

have frequently heard

satisfactory.

It

is

substitute for good

The

said that the lowest bidder

is

entitled to the

work returned if not found

specifications may be made a

must

castings,

due

all

strate his ability

is

them up

an error to assume that

workmanship and

strict

service.

cost of applying specifications that are not respected, the

delays, the losses

It

it

that he will be held to the specifications and the

to defects discovered

only after

work

manufacturing

has been done on the

be added to the lowest bidder's quotation, unless he can demon-

and the high character of

his product.

our fixed purpose to keep Precision Die-Castings and

to the highest

'the service back of

commercial standards and quote the lowest prices that this

policy will permit.

Estimates are prepared from models or blue prints, preferably models, or both

when

the

model

are submitted,

is

we

not accurate.

exists as to the suitability of the

tested.

cast

may

We

In die construction,

follow the prints

if

metal

there

we

is

when both models and

any difference.

propose to use,

will furnish ingots for this purpose

it

When

should be thoroughly

from which the parts

be poured in sand and machined to size.

prints

any doubt

If the parts are

to be die-

found

satisfac-

our die-castings will be found even stronger and better, due to the added
strength given by the pressure and rapid chilling in the dies.
tory,

Aluminum pump

17

shaft housing cover.

Liberty motor.

The

information given

when

orders are placed or estimates requested, should

We

suggest that the following points be given con-

be as complete as possible.
sideration

and that we be advised

them

fully concerning

1.

Electrical conditions under

2.

Temperature conditions

which the parts will be used.

will they be subjected to heat

or cold.
3.

Will they be used indoors or

4.

Will they be subjected

5.

If there are

to

out.

hard shocks, strains or wear.

bearing surfaces under what loads and speeds

will they operate.

6.

Will the parts come

contact with water, moisture,

in

gases, or corrosive liquids.

7.

Will they come

8.

Will the parts be

in contact

with foods.

finished

how

so,

if

(plated, baked

or cold enameled, polished, etc.).

9.

10.

How

will the parts be assembled and used.

When

several parts are submitted they should be

bered or
11.

If

named

they must

fit

num-

to avoid confusion.

other parts not furnished by

us,

such

parts should be furnished, with suitable gauges and the

kind of
12.

fit

specified.

If several parts are

in sets so that

13.

When

Between what

a complete

is

wanted, will they always be ordered

may

points,

if

be

made

any,

is

in

it is

always best

usually conveyed by the model

combination

dies.

special accuracy required.

model or an assembly print

will be used can be furnished,

needed

they

to

of the device in

do

itself.

New

which the parts

most of the information

so, as

inventions or devices or

designs not yet published or on the market will, of course, be treated as confidential.

New

devices should be thoroughly tested and exact models built before the

dies are constructed, as

Our wide

it is

sometimes expensive and

difficult to alter dies.

experience in applying the use of die-castings to every field in which

they are used, makes the services of our engineering department very valuable to

our customers.

Our

sketches or drawings

engineers will gladly assist in the design of parts and prepare

embodying

their suggestions.

most approved methods of handling,

ings will be found of valuable assistance.

Aluminum mold

insert for cord tires.

Their advice on the

finishing, assembling

latest

and machining

and

die-cast-

Metals

III.

The

Conditions which Restrict

process

such in

is

its

very

nature that only a very limited

the Selection of Metals Used

number

of alloys can be die-cast

commercially.

have a fusing point and shrinkage which will not be so great

Such metals must

as to injure or destroy

the metals of which the dies and casting machines are made.

The molten

metal to be die-cast must be held

subjected to high pressure.

since

compression chamber and

in a

Aletal must be used for the compression chamber,

no other material has the required strength and wearing qualities

at the

necessary working temperatures.

Metals when molten have

a tendency

with other metals coming

to alloy

in

contact with them, even though such metals are far below their fusing tempera-

For

ture.

instance,

molten zinc

and gradually destroy the

and

after an excessive

pot.

amount

in

an iron pot will eat away part of the iron

The

dissolved iron forms an alloy with the zinc

of iron has been absorbed, the zinc

The

able for use.

becomes unsuit-

metals which

be die-cast are therefore

be handled in metal pressure

results,

chambers and

The
a

dies.

degree of pressure applied has

marked

ity of

may

limited

which may with practical

those

to

first

effect

on the grain and qual-

the work.

Pressures applied by

the Precision process vary

1000 pounds

to

from 200

to

the square inch, ac-

cording to the work to be produced.

The

casting or pressure

chamber must

therefore have a high tensile strength

at

temperatures ranging between 800

1300

and

F.,

the

points

between

which die-castings are poured.

The
the

velocity at

dies

which metals enter

tremendous,

is

and

at

the

temperature used will quickly destroy

dies

made from poorly

selected metals

or not properly treated and prepared.

The

shrinkage of castings in the

dies subjects

wear.

when
D
,
raris

for motors, instruments, cameras, stamp

Aluminum, tin and zinc alloys,

affixers, etc.

19

J.

the

them

to great strain

This problem does not

and
exist

casting in sand, as in that case

metal

mold with

in
it.

shrinking
^

carries

the

Phonograph
and sound

The

metal to be die-cast,

elasticity, as

Aluminum
to great

when

solidifying,

otherwise in shrinking against cores

fall
It

is

tour arms
Zinc alloys.

amount

of

will crack.

which they shrink

substantially below their

apparent, therefore, that

the shrinkage and tensile strength of the metal to be die-cast exceeds a cer-

tain point,

no die material

may

be found which will withstand the strain.

Another important consideration

die-cast,
in the

a certain
it

alloys subject the portions of the dies against

wear, as they have a high shrinkage and

fusing point before being removed from the dies.

when

must have
in the die,

clboivs,

boxes.

is

in

determining the metals which

may

be

the necessity' of maintaining the metal continuously in a molten state

machine or

in

an adjacent crucible.

In some metals this causes excessive

oxidation and occlusion of gases and impurities, resulting in porous, imperfect

castings of

low

tensile strength.

20

This condition does not

sand molding, as the molds are

exist in

and the entire pot of metal then poured

The

die-casting

first

prepared

comparatively short space of time.

in a

machine operates onl\ one mold, but works

it

continuously, requir-.

ing that a given quantity of metal be constantly in readiness for casting.

The

metal formulas used by us are the result of long study and

many

experi-

ments, as well as of our observation of die-casting metals in use over a long period

There

of years.

are a great

formulas and guide us

many important

in the selection of

These considerations involve

almost as

much

considerations which govern these

the metals used for anv particular work.

the conduct of the metal in the casting machines

and lasting qualities of the castings.

as the strength

Strong, solid

and accurate castings cannot be produced from metals which by reason of their
sluggishness, shrinkage, fusing point, tendency to dross, brittleness at high tem-

peratures below fusing,

etc.,

seriously interfere with production in the casting

machines.

For these reasons

This

it is

very important that the formula be strictly maintained.

not an easy matter

is

when metals

are kept in a molten condition for long

periods due to their tendency to separate in layers according to their specific

gravity.

While
means

the molten metal

in the casting

is

machines we constantly

stir it

bv

of a device attached to the machine, keeping the formula constant and

bringing oxides, gases and impurities to the surface.

Up

to this time the difficulties involved in casting brass, bronze, iron, steel,

nickel alloys, etc., have stood in the

way

of the process to these metals, although

commercial application

of the successful
it

is

not unlikely that

in

the next

few

years brass die-castings will be produced commercially.

Y)'lQ

AlloVS

C^astinp"

^^^^ tables on

p.

The

83.)

Precision Castings

Co., Inc., maintains a laboratory in charge of the

chief chemist,

who

also supervises the

foundiy

in

which

metals are mixed.

all

He

or his assistants, personally check up all weights before the metals are mixed to

prevent variations

formula.

in

All metals used in the foundry can be obtained

from stock only on the chief chemist's

requisition.

The

strictest supervision in

maintained to avoid the production of inferior metals, either through insufficient

or too

much

heat,

and the temperature of

all

molten metals

is

constantly watched

with pyrometers.

Our

laboratory

is

specially equipped for the testing

men

in

charge have the advantage of

metals, and the

this particular

They employ

work.

the best

and treatment of white

many

years of experience in

methods for refining metals and know

the sequence to be followed in combining the alloys.

Pouring temperatures are

carefully watched and the proper fluxes and de-oxidizers used.

question, therefore,

modern

science

There can

be no

that the results obtained are the best that experience and

make

possible.

Excessive impurities in die-casting metals are very harmful and also greatly

reduce and hinder production.

21

We

use onh- the purest metals suitable for the

All metals are analyzed for impurities before acceptance, and rejected

work.

For

they exceed our specifications in any particular.

is

when metal

this reason

if

cost

an important factor, we cannot always compete with concerns using the ordi-

nary or low grade metals, although

equipment enable us

to

overcome

many

in

cases our

manufacturing methods and

this cost difference.

Alliminiim AlloVS The

most satisfactory aluminum alloys

those generally

20%

known

in

die-cast are

aluminum-

the trade as

Aluminum-copper alloys are

stronger and harder than pure aluminum and are more easily finished and maThe tensile strength of our die-cast copper-aluminum alloys runs between
chined.
copper allocs and contain from

18,000 and 21,000

The

to

5'/'

the square inch.

lbs. to

high compressiv'e strength of the copper-aluminum alloys

(AU

formation of a needle-like eutectic

tically

as

copper.

They have

pure aluminum.

cu.

and Al.) which

is

due

is

imbedded

to the

in prac-

nearly the same general chemical properties

pure aluminum.

Comparative figures of the properties of sand and

(92%

Al. and

8'/(

copper), show that the die-casting has

No. 12

die-cast

20% more

and almost double the percentage of elongation.

The addition of copper to aluminum, besides increasing the

alloys

elastic limit

tensile strength,

reduces the fusing point and shrinkage, making the metal more suitable for diecasting.

In die-casting aluminum

not always practical or desirable to hold to any

it is

may be increased or reduced as the casting conmay be made with satisfactory results with as much
when the design of the piece or its functions require.

particular copper content, but this

ditions warrant.
as

21%

More

8%

or

than

or

22%
23%

10%

Die-castings
of copper,

copper

is

of copper

is

rarely,

if

When

ever, used.

casting in sand

formation of large crystals and

in

The

consequence produces a brittle metal.

rapid and almost instantaneous chilling which takes place

die-cast prevents the formation of large crystals

much tougher

more than

not frequently used, as the slow cooling permits the

when

these alloys are

and therefore produces

very

metal.

Zinc strengthens aluminum more than copper or manganese, but it is not

which the metal must be main-

suitable for die-casting as the high temperature at

it to burn out and dross excessively, destroying

These metals should only be used under condi-

tained for extended periods causes

the good qualities of the alloy.
tions

which permit immediate pouring after melting.

presence of zinc in aluminum-copper alloys causes

The

needle-like eutectic to be
as the zinc

is

thrown

aluminum
proven.

is

number

of the

must be decreased

Eurojjean practice has favored these alloys over the alumi-

raised.

num-copper, owing to their somewhat greater

practice the zinc

a great

out, so that the copper content

generally omitted.

alloys fail

They should

in

time under

tensile strength,

It has

stress,

but in American

been asserted that zinc-copper-

but this has not been satisfactorily

not be die-cast because of the drossing of the zinc.

In

saline solutions, galvanic action causes such alloys to deteriorate rapidly.

22

Tin

has never been a satisfactory metal for use in conjunction with

in die-casting.

and the alloy

It
is

makes the metal too

As

not as strong.

Manganese-aluminum

alloys

tin

may

brittle,

is

copper-aluminum

aluminum

brittleness increasing in time,

also expensive

it

is

rarely used.

also be used, but unless used for special

purposes they present no substantial advantage

qualities over the

its

in

strength or general commercial

alloys.

Under normal markets aluminum, though comparatively high in cost per

is really no more expensive than the cheaper white metals, due to its low
For instance, a casting weighing one pound in No. 12 aluminum
specific gravity.
pound,

alloy will,

if

made

in the

following metals, have these weights

Copper

3.2 lbs.
3.0 "

Brass
Cast Iron

is

as

2.6

"

Lead

4.0

"

Zinc

2.5

Bronze

3.1

"

Lead and aluminum do not "mix", having no affinity

in aluminum, but can only be present
Tin in aluminum-copper
the metal will not "hold it".

harmful impurity

for each other.

in

alloys

is

harmful.

causes excessive brittleness in time and the castings will disintegrate.

than \y2'/( to

2%

of iron should be present in

metal will become too

brittle.

Alumiuiim brush holders for

23

Below

electric

that

motors.

aluminum

amount

iron

is

Lead

very small amounts

It

Not more

alloys as otherwise the

not harmful.

Electric instrument frames, tin olloys.

Properties of Pure
softer

and more porous than

Aluminum
its alloys.

^"''^

aluminum

used

for

not generally

is

because

castings

it

is

strength and hardness are considerably

Its

It may be rolled in sheets .005" thick.

increased when it is compressed or rolled.
Gold alone is more malleable. The metal has excellent tonal qualities which are

improved by the addition of

The
Scale.
It

is

silver.

pure metal

electrical conductivity of the

It

practically non-magnetic

is

and

is

is

about 62

sometimes used for power feeders and high tension transmission

conductivity

Its heat

only by copper

The

among

is

Matthiessen

in the

an excellent conductor of electricity.

lines.

greater than zinc, iron, tin or steel, and

exceeded

is

the baser metals.

specific gravity of

ordinary grades

is

2.68,

making

it

about ten twenty-

sevenths the weight of cast iron.

Shrinkage per foot

common metals
Aluminum

.2031".

is

and

its

OI

is

due

to the absorption of oxides, silicates,

^^^^

natural

solvent

chloric acid.

/\lUminum

It

and other

of

aluminum

is

hydro-

slowly attacked by either

is

hot concentrated acid dissolves

is

the

concentrated or dilute sulphuric acid, but the

dilute or concentrated nitric acid have little effect

It

among

exceeded

high shrinkage.

Chemica.1 PrOOertieS

expansion

melts at 657 C. or 1215 F. and develops weakness at solidifica-

tion tending to cause cracking,

impurities,

Its linear

by zinc and lead only.

not affected by sulphur at

Organic secretions and

practically none.

For

cal instruments.

The

less

salts

this reason

and

it

Cold

readily.

act but slowly

when

hot.

than red heat.

have
it is

little effect,

and vinegar

(4%

acetic acid)

sometimes used for dental plates and surgi-

acids in foods have little effect

and when any action takes

place the chemical products are harmless, which makes the metal well suited for

kitchen ware.

Contrary
sea waters.

to

an impression frequently held,

Strips of

it

aluminum were placed on

is

not affected by mineral and

the side of a

wooden

ship and

were found to be corroded less than .005" after six months exposure to sea water,
whereas copper under the same conditions corroded nearly twice as much.

Aluminum may, however,

be

made

to corrode rapidly in salt

water by being

held in contact with another metal such as copper or iron, causing galvanic action
to take place.

As most metals

are electro-negative to

under such conditions, resulting

metal.

When,

therefore,

in

aluminum

the
is

aluminum, a

voltaic couple

is

formed

rapid corrosion of the electro-positive

used under such conditions,

it

should be

insulated from the electro-negative metals with a good insulating material such as

rubber, or a heavy coat of insulating paint.

Aluminum

is

not attacked by carbonic acid, carbonic oxide, or sulphuretted

hydrogen.
24

A eroplane
the U. S.

speedometer made for

Government. Aluminum.

Measures speed by wind

Aluminum
iorate,

velocity.

has been said to absorb nitrogen from the

but experiments recently

any nitrogen bubbled through

made have proven

it

air,

causing

it

to deter-

that the metal does not absorb

for several hours, although

it

may under

such

conditions retain a minute trace to no harmful extent.

Solutions of caustic alkali, bromide, chlorine and hydrofluoric acid attack the

metal quickly.

The common

impurities are silicon and iron.

for iron, being in the

same chemical group.

Aluminum

has a great affinity

Impurities in excessive quantities

materialh' reduce the resistance of the metal to corrosion.

2^inC A-lloVS

^^^^ tables,

p.

Zinc alloys containing various propor-

83.)

tions of tin, copper

and aluminum or only one or two of these

metals, have been used since the inception of the die-casting industry.

comparatively cheap

among

the white metals, but considerably

than cast iron, which they resemble

in

are

strength and brittleness.

Precision zinc alloys vary between 12,000 to 16,000

lbs.

tensile strength to

the square inch, according to the design of the part and formula used.
25

They

more expensive

They
headings.
tact

ma}' be plated,

They

with moisture.

about 150

but

F.,

finished

and machined

as

described

under separate

should not be used for food containers, and are corrosive in con-

They should not be used under heat conditions exceeding

may temporarily be subjected to between 250 F. and 300 F.

according to the formula.

Pure zinc
alloyed with

too brittle and soft to be die-cast and flows sluggishly.

is

When

copper or aluminum the crystals are materially reduced, produc-

tin,

ing a finer grain and a

thereby reduced and

it

increases the strength

much tougher and

flows

more

readily.

stronger metal

The

its

shrinkage

is

also

rapid chilling in the die greatly

and toughness of the metal.

Tin alone does not increase the tensile strength or hardness but softens the
metal, makes it flow more readily and prevents a certain amount of shortness or
cracking.

In excess of about

8%

it

performs no useful function and does not

combine well.

Copper toughens and strengthens

3/^%,

as then

it

the metal but should not be added over

increases the fusing point to such an extent that excessive dross-

ing and oxidation are caused in the casting machines.

Aluminum

is

wonderful de-oxidizing agent, reducing the dissolved or im-

prisoned oxides within the metal and forming alumina which floats on the surface

Upper center and

shafts.

loiver

left,

s-ci-vel

joints

for flexible speedometer

Other parts instrument and speedometer frames.

Zinc alloys.

26

is skimmed off.
aluminum oxide on

and

It

also valuable because

is

it

forms a very thin coating of

which prevents the

the surface of the die-casting

small percentages also makes the metal flow more readily and

and toughen the

qualities strengthen

last

More

alloy.

not be added in zinc alloys containing

than yS

of

from

alloA'

Aluminum

soldering or sticking to the dies, due to the affinity of zinc for iron.

aluminum should
(See

will cause deterioration.

tin, as this

in

de-oxidizing

its

paragraph below.
All metals

when molten have

tendency to absorb atmospheric and fuel

This

gases; oxides also are occluded and held mechanically within the metal.
latter property

is

well illustrated in the thick scum on the surface of zinc alloys

before fluxing, which consists of an intimate mixture of metals and oxides, and
rises

to the top because of its

lower

oxides the most suitable flux used

is

To

specific gravity.

sal-ammoniac.

and hydrochloric acid

and

the clean oxides are then

skimmed

into

ammo-

from the oxides

the volatile chlorides free the metal

nia

from

free the metal

This decomposes

off the surface.

Zinc, or spelter as

PrODertieS of Pure Zinc

is

it is

known

in the trade,

bluish white metal, hard and brittle

and coarsely crystalline when the pouring temperature is much above the melting
point, but more granular when poured near the melting point, which also makes
it

more malleable and more

Rapid chilling greatly reduces the

resistent to acids.

size of the crystals.

In dry

air,

pure zinc retains

its

lustre,

but moisture causes

it

ered with thin greyish white coat of basic carbonate which protects

Pure zinc in sheet form was exposed on a roof

and showed oxidation of only .004".

corrosion.

in

become cov-

to

from further

it

Bavaria for 27 years

In the presence of impurities or \\hen cast with other metal,

loses

it

non-

its

corrosive qualities to greater or lesser extent, according to the circumstances.

It

not blackened by hydrogen sulphide fumes or solutions as are copper,

is

silver, lead, etc.

ble

in

other

It dissolves readily in nitric acid,

acids.

Ordinary zinc

and sulphuric

hydrochloric (muriatic)

but

when pure

(prime western grades)

acids.

is

almost insolu-

will

dissolve

Caustic alkalies dissolve

it

in

more

slowly.

With

the exception of

positive of the

common

aluminum and magnesium,

metals.

In consequence

it is

zinc

is

the most electro-

easily dissolved

when

in the

presence of caustic alkali and in contact with electro-negative metals, such as iron,
tin or copper, all

(See table,
is

p. 86.)

of

which are below aluminum

undesirable for the same reason.

formed, resulting

in the

cal action of the negative

is

ele-

force produced by the difference in potential or chemi-

and positive metals.

for this reason that zinc alloys containing copper, tin

corrosive in the presence of moisture.

27

the electro-chemical series.

immediate and severe attack of the electro-positive

ment by the electro-motive

It

in

aluminum in the zinc-tin-copper alloys

Under these conditions a voltaic couple is

high percentage of

By

and aluminum are

care in the preparation of the alloy

may

this corrosive action

up

in the Precision

num

aluminum content

are both present the

T^-p-j, j^|-|-jpo

With

be reduced.

7{t\C

j|-j

Low

in

view, alloys of zinc

The common

the

of

die-casting

weaken

proposed revision of standards as of

March

Testing Materials divides spelter into

five

it,

tin

8,

is

made

and alumi-

consideration.

and produce

cadmium and

impurities are lead, iron,

poor

finish.

Under

arsenic.

the

1917, the American Society for

grades as follows:

Lead

Iron

0.07
0.20
0.60

0.03

0.07

0.10

0.03
0.03

0.80
1.60

0.04
0.08

0.50
0.50
0.75

0.50
1.00
1.25

High Grade*
Intermediate*
Brass Special*
Selected*

Prime Western
*It shall be free

when

held to very low limits.

is

affect the lasting qualities of the metal,

Cadmium

end

grade spelters should not be used when the

quality

They

this

laboratory are very low in impurities and

Total

Vc

Cadmium

% not over

from aluminum.

makes the metal short, and causes cracks in shrinking.

Lead is not as injurious as cadmium, arsenic or iron. Zinc cannot hold
more than 3% of lead except when liquid. At 788 F. it will hold 1.7% and at
over

1200 F. 5.6%.

.30*/^

Lead should not be present

make the zinc

Iron above .13'/ tends to

it

makes the metal

easily reducible to a fine

cannot be kept out of die-castings,

as the

in zinc die-castings
brittle.

powder.

metal

is

over

1%.

In substantial proportions

certain

amount

of iron

absorbed in the pots of the

machines.

Arsenic over

.05%

has the same effect as iron and in large proportions, due

to its great affinity for iron, will cause the

of the die-casting machines

more

metal to attack the iron pots and parts

rapidly.

Bouchon for hand grenades.

O^er 25,000,000 madtt for
the U. S. Go--cernment.

28

Babbitt bushings.

Tin AlloVS

(See tables,

p.

83.)

Tin when

die-cast

is

usually combined

with varying proportions of antimony, copper and lead or

only one or two of these metals.

It

may

also be cast pure.

Tin

alloys are not

brittle, they have low tensile strength but are easy to cast because of their low
Very small or
fusing points and the fact that the metal flows readily in the dies.
are
for
that reason
alloys
aluminum
or
zinc
in
be
cast
cannot
delicate parts which
accurate
and
more
them
makes
shrinkage
Their
low
alloys.
often made in tin

largely avoids cracks in casting.

29

They

are not corrosive in the ordinary acceptance of the term and

used for parts coming

when no

contact with food

in

lead

in the alloy.

is

may be
They

are not affected by moisture and are slowly affected by alkalies and mineral acids.

(^ne of the chief uses for the tin alloys

known

anti-friction metals

ead AlloVS

allov with

is

composition of bearing or

in the

as babbitts.

Lead

^^^^ table,

p.

83.)

antimony

in

substantial

c(jpper, except in the presence of tin

ture and under conditions which render

it

is

usually alloyed with tin and

proportions

will

it

and antimon\

and

not readily

at a

tempera-

impracticable for ordinary uses and

particularly for die-casting.

Lead

come

alloys should never

with them, forming basic lead

salts

in

contact with food, as organic acids react

are insoluble in

and readily

dilute sulphuric acids, dissolve slowly in hydrochloric,

They

They

which are poisonous.

in nitric acid.

are not affected by moisture and are non-corrosive in a commercial sense on

exposure to the elements.

They

They have

are cheaper than the tin alloys, but not nearly so tough.

similar casting properties and are greatly toughened by the rapid chilling in the
dies.

T\ pe
to the

metals

all

have

a lead base

There

requirements.

outside the printing trades

it

One

ened with antimony.

and are made

metal used

is

usually understood to contain merely lead, hard-

class of type metals used for printing contains

77%
1%%

5%

in linot\pe

to

53%
26%
18%

to

3%

to

to

machines contains about:

83%
14%

Lead
Antimonv
Tin

3%

:.

(See tables,

j-j4-i_p-t-ip-j-jQj^

i.r

LL

-Q

Metals or babbitts
1

the friction

p.

In a perfectly adjusted and

83.)

lubricated bearing, there

5^^,^,^^^

the journal

Such

oil.

a perfectly adjusted bearing

and the purpose for which babbitts are designed

effects

a thin layer of oil

is

is

to

never attained in prac-

overcome the harmful

which are brought about by actual metallic contact between the journal

and the bearing due

This
plastic

would be

and the bearing; the metals

would not actually touch each other at any point and

would not be between the metals themselves but between the metals

and the film of

tice

formulas according

no standard type-metal formula and when used

Lead
Antimonv
Tin
Copper

The

to various

is

is

done

enough

to

to the necessarily inaccurate

two ways;
conform to the
in

as perfectly as possible

ble to reduce friction

first,

and uneven surfaces.

by making the body of the bearing metal

inequalities in the journal, thereby fitting itself

and second, by making the bearing surface

as

hard

as possi-

and wear.
30

Babbitt bearings for combustion motors.

31

The

softer a metal, the greater

is

its

Hard

co-efficient of friction.

metals

require greater pressure to produce the same friction as soft metals.

Hence

alloys containing

hard crystals imbedded

matrix answer

in a plastic

the general requirements of most bearing metals, the hard cystals reducing the
frictional contact, and the body or matrix adjusting itself to the size of the journal.

representative babbitt formula

is:

89.1%
7.2%
3.7%

Tin
Antimony
Copper
In this and similar metals

two groups

of metallic

compounds

and the other of

ant.),

Sn Cu (Sn Cu;; 38.5

These compounds form
ties

and copper, corresponding

tin

tin to

61.5 copper), and

the hard crystals

Cu

tin

50%

and

formula Sn Cus and

to the

Sn

are formed, one

(49%

of tin and antimony corresponding to the formula Sn Sb

55

which furnish the

tin to

35 copper).

anti-frictional quali-

of the metal.

By adding

a small percentage of

aluminum, babbitts are made considerably

and wearing

closer in grain, resulting in greater durability

The

qualities.

rapid

mold when die-cast also toughens and strengthens the metal to such
Bearings
an extent that hammering or compressing the bearings is unnecessary.

chilling in the

poured
results

hot molds or not chilled are considerably softer, and to give good

in

must usually be compressed before they are assembled

motor.

The

roller.

If this

much

general practice

is

to set

a combustion

in

them up and run through an expansion

not done such bearings will compress in service, leaving too

is

clearance between the bearings and the shaft.

For many purposes, when pressure

known.

the best bearing metals

antimony

13%

a eutectic

the antimony content

is

is

is

formed which

raised,

light,

Combined
is

crystals of

antimonial lead alloys are

in the

four times as hard as

free

antimony are held within the

and when these crystals become numerous enough

eutectic,

among

87% and
When
lead.

proportion of lead

to

come

in contact

with

each other, the load on the metal, instead of being transmitted through the eutectic, is
is

taken up by the antimony crystals, and the metal

the case

when more than 23%

Copper up
them.

allo\s,

21^2% will

also be

When

the metal.
\0'/(

to

Tin may

is

too brittle for use.

when

raise the fusing point of such alloys

high pressures are encountered, tin

is

F.,

should not contain more than

10%

a desirable

of tin, as

when

element up to

Lead bearing

more than that

will

the bearings run hot.

have manufactured babbitt bearings for the largest motor builders for

having grown up with the automobile industry.

favorably

and toughen

used for heavy loads or under conditions which develop heat above

reduce the fusing point and cause "squeezing out"

We

This

added which will reduce the fusing point and toughen

reducing brittleness and lending rigidity to the bearing.

about 250

years,

is

used.

known wherever motors

engineers have succeeded

in

are built.

producing

Our

"Precision" bearings are

metallurgical chemists and

a series of babbits of various

grades which,
32

while equal to the finest babbitts made for the general trade, are at the same time
designed so that they will be toughened and hardened more by the die-casting
process

we

subject

them

to,

than ordinary metals.

Ball bearing retainers

and babbitt bearing shims,
tin

33

and zinc

alloys.

Precision Castings Co.'s die shop in Fayetteville plant.

Dies, Die-Design and

IV.

Construction
Die-casting dies probably present more difficulties

than any other

dies.

Their

life

piece,

made, the care they

having many moving

under the same conditions.

play in the

life

receive, etc.

The

factors are satisfactory.

workmanship

and

in

them, the design

Naturally, a die for a delicate

cores, w^ill not last as

long as a simple die

important part which workmanship and material

of a die, as well as in the quality of

sized too strongly.

lion.

slides

The

design and

and the castings made

acter of metal used both for the die

of the piece to be

in

depends entirely on their construction, the char-

its

product, cannot be empha-

wise buyer will never question a die charge

Some

dies are

if

other

good for 25,000 castings, others for a mil-

Precision dies are built for endurance irrespective of expense, as

we

are

equipped especially for quantity production and consider the best dies the cheapest
in

the end.

We

shoulder a large part of the die cost ourselves to avoid any

tendency on the part of customers to save unwisely

in

such expenditures.
,

34

realises of

Tnarnirarv

Although design and construction have

important bearing on the accuracy,

in

Lja.Sting'S

grain of the castings,

cult to determine

it is

finish,

frequently very

whether defects

in

most

and
diffi-

castings

are due to dies or other causes.

Inaccuracy
castings,

it is

may

be due to a

number

of causes.

almost always due to an error

warping of the

If constant,

i.

e.,

alike in all

in the size of the die, or a shifting or

die parts.

Precision dies are cut from solid blocks

whenever possible. This is often

more expensive than "building up" an impression but it is much more satisfactory
in results.

Many

constructions, due to the design of the part,

out of several pieces and in such

work

must be "built up"

the greatest care should be used.

Molten metal under high pressure will creep into the slightest crevices. All
must therefore be perfectly fitted. The high pressure and hard w^ear to

die parts

which they are subjected require substantial construction.

Long practical experwork of this kind.

The heat at which dies are worked and the constant heating and cooling
which take place will cause them to warp badly if steps are not taken to overcome
ience

is

this.

necessary to properly direct

For

this reason all dies are heat-treated to take all the internal strains out

of the metal and protect

its

surfaces from the destructive action of the molten

metal.

Wheel Die. Part cast from it shown in

The belt groove is formed by two slides,
shown in open position. The slides are operated
by a single lever as shown. The dowel pins shown
on left die-plate pass through the slides when closed
Pulley

center.

and hold them firmly

in position for the casting

operation.

35

Number Wheel

Die.

Engraving;

slides are fastened to rollers

is

which

formed on the 12

travel in the

cam

slides.

These

slots in the circu-

back of the slides. By moving; the lever attached to the plate

back and forth the slides are withdrawn or put in place. The plate on
the extreme left fits over the slide mechanism to protect it. The die is
lar plate,

g;ated throug^h the center, a sprue cutter beings used.

When
a

number

inaccuracy varies in different castings of the same run

of causes.

ticles of dirt or

ing machines

it

If the error

is

across the parting line

metal on the die surfaces, holding them apart.

may

may

it

may

it

In old style cast-

be due to wear in the clamps and toggles used to hold the dies

When

shut, or to their weakness.

a casting

is

made, the pressure under which

the molten metal enters the die has a tendency to open the dies and

made the strain on the dies is great, running

Precision power driven die-casting machines do not

castings are

are not dependent on mechanical

shut under

much

means

greater pressure than

no likelihood of undue variation from

Undue
inaccuracy.

is

to

large

use clamping devices and

keep the dies closed.

They

are held

exerted to open the dies, so that there

this cause in

is

our work.

variation in die tempearture, especially in large parts, also causes

There

are a

number

steady, the die position fixed

of features in our process peculiarly suited to

and temperature

is

constant and

fully controlled.

Precision dies are water-cooled and their temperature control

of regulation used to control the flow of water, but

tions are unfavorable, such as irregular operation

is

when

as high as 15 tons.

die temperature control in that the operation of the machines

means

be due to

be due to par-

if

lies

in

the

the operating condi-

and heats, temperature control

useless.

36

moving

If

parts of dies are cheaply constructed through a desire to save time

or material cost, or through inexperience, a great

way

many

difficulties

may

beset the

Metal pressure may open

and lubricated wear will result,

of the user as well as the producer of die-castings.

If they are not properly fitted

or shift cores.

causing inaccuracy.

Dies should be so constructed that they

may

easily be taken

oughly overhauled and cleaned after a certain period of

"r)jp

A gcpppkly

side of the die

is

Each die is complete in itself and holds

mechanism needed for its use. Attached

an iron box,

in

down and

thor-

use.

all

the operating

to the ejector pin

which are mounted core and ejector pin plates

Separate slides and cores are mounted on

which are operated by rack and pinion.

the die according to the design of the part to be

dles or gears.

They

operation, and locks to prevent their being

Die

made and

are operated with han-

are usually fitted with safety devices to prevent improper

moved by

the metal pressure.

^^^ ^^^ surfaces coming in contact with molten metal must

Slirfa.CeS

be polished for finish and to prevent the castings

hering to the
tool

All surfaces rubbed by the castings

dies.

in ejection

marks or depressions and must be absolutely smooth and

free the casting the

moment

on the circumstances

in

it

begins to

move

out.

each case (see page 52).

from ad-

can have no

slightly tapered to

The amount

of taper depends

Theoretically a casting could be

Parts of die for aluminum steering; column sector.

Extreme
cast iron die-box with pinion which operates ejector pin
plate shown next.
Next is the plate throug^h which the ejector
pins pass and on the extreme right is shown the other die-plate.
Below this is the core mounted on bracket with operating handle, which forms a hole in the casting.
The casting as it comes
from the die is also shown.
left

37

Die block in process on millings machine. Below is shown wood pattern of the part to be
made.
Note that the die impression is being milled out of a solid piece of steel instead of
being- built up in sections.

withdrawn without draft but

in practice

The

true surface w^ithout warpage.

it is

impossible to maintain an absolutely

undercut will crack the casting

slightest

in

ejection.

"^"'^^'

Cja.tinP"

S'lt^i'ig

"f castings

rules can be applied.

is

the subject of constant study and no fixed

Castings, according to their size and design,

are affected by the width, thickness, shape and location of a gate as well as by the
direction in

which

it

Improper gating will cause poor

enters the casting.

finish

and porous castings.

Die

^"'"

N4a.tGria.ls

'^''^'

machine

^'"^

'^'^'^

steel.

le^d parts the die impression

Except for special purposes

be hardened as the expansion and contraction will cause

Cast iron

make
steel

is

seldom used for

castings stick to

it

it

it

to crack

die impressions because its porosity has a

and show poor

It

finish.

is

is

made

and check.
tendency to

not as easily worked as soft

and cannot be bobbed.

Drill rod and tool steels are used for ejector pins and cores, slides, etc.

machine

steel

cannot be used for aluminum.

alloy steels for

aluminum

dies

instances over 200,000 castings

We

were taken out

may

in

drawings or models.

be calculated accurately.

When

The

service.

In several

of a single die.

Shrinkage of castings
for in

should be made

Soft

have developed several special

which have given wonderful

Shrinkage Allowance in Dies

ance

of

should not

is

allowed

the dies, so no allowance

simple pieces are

made

this allow-

shrinkage of complicated pieces

is

held
38

back by portions of the die against which they shrink and the amount of shrinkage
in

many

Long

such cases can only be approximated.

skill in this respect

and by working "safe", that

metal from the die any inaccuracy

may

experience develops great

by taking a

so that

is

more

little

be overcome, wonderful results are ob-

tained.

Changes

Cha.nP'eS

in dies

as possible.

therefore, to

when on

add metal

the other

a difficult one.

but

it

is

It

hand

may

may

The

to a part
it is

be

die
it

is

made but

it

is

best to av(jid

them

as

much

the exact opposite of the part to be cast,

need only be taken away from the

necessary to add metal to a die, the task

be done b\ inserting pieces in the

form

is

die,

but

frequently

of plugs or strips,

not practical to weld pieces to a die-impression.

weaken the die construction or compel the use

tion, which could of course be avoided if the

of inferior
die

Changes frequently
methods of die construc-

had been

laid out for the final

design in the beginning.

It

is

much better to
new designs

changes or

element of experiment

take the time to build models and thoroughly try out

before building or changing dies.

in the

all

There should be no

production of die-castings as the process can only be

used economically for quantity production of identical parts, and the dies should
be used as

first

designed.

"t
i>~

.'^^

^'^^

Assembled
made from

39

die
it.

and plate
Zinc alloy.

C^rOSsinP"

and

^^

Inter-

^^

better practice to avoid cores or slides

P^^^ through each other.

Ul
r^
(^OreS
changeable

through a large core

is

apt to strike the larger

core, raising a burr, or injuring

This will occur

core.

from taking

its

if

or

two

When

proper position.
is

it

two or more parts

details are

wanted,

it

of the
is

the design cannot be modified to avoid

usually better to machine or drill that part of

which requires the undesirable

When

one or the other

the smallest particle of dirt prevents the larger core

die construction of this kind

the casting

which

small core passing

die construction.

same general

design, but differing only in one

frequently possible to

make them from

a single

impression by using interchangeable plugs or cores in the die.

r^QiyKjpnt-JQrj

F)ieS

When

combination dies containing two or more

impressions of different parts are used,

it

good practice to shut off any of the impressions so that only certain ones
cast,

but the entire set must always be made.

not be

made

For

is

may

not
be

this reason such dies should

unless the parts will always be used and ordered in complete

sets.

Die maker
"Checking
up."

40

removable although they are

l^recision dies are not

RemOVa.1 of Dies

held for the exclusive use of the customers to whose

order they are

made and who pay

work

cost of the

part of their cost.

The

of the die cost in our die charge.

We assume

to us.

rate charged

We

include only a portion

less

than the actual hourly

full responsibility for the perfect condition of

the dies perpetually without charge, except

sign are ordered by the customer.

is

We

when changes which

affect their de-

also provide for insurance

and assume

all

the risk.

The
many

design of Precision dies involves skill and experience,

years of effort which

we do

not wish to

make

the result of

generally available.

are also best fitted for use on Precision machines and

require material changes, which might produce wholly unsatisfactory results.

are easily injured in shipment or
to their delicate

when handled by

They

used elsewhere would

if

Dies

inexperienced workmen, owing

mechanism and heavy weight.

The removal

of dies

is

not permitted by the leading concerns in the die-cast-

ing industr}^, and in other fields such as forging, stamping, rubber and composition

molding,

The

etc.,

a similar

custom

prevails.

dies represent an investment

on our part which will be useless

without the good will and patronage of those for

must always be our aim

to

make

is

to

many

years),

its
if

standards and

alloys.

it

at-

the business of the

continue to grow and prosper.

Handles and knobs.

Aluminum and zinc

41

to us

they were built, and

Precision Service high in

tractive in cost (as has been our practice for

company

whom

Die-Casting Design

V.

Die-castings present entirely different problems in designing the parts to better

adapt them to the process of manufacture than do sand castings, forgings or

machined

parts.

Slight variations in construction or design frequently greatly

reduce the cost and increase the strength and efficiency of the parts without inter-

Only those who have a very wide and thorough

fering with their functions.
experience in the art of die-casting, combined with a good knowledge of mechanical

and production engineering, can take

full

advantage of the

possibilities the die-

book are many

in the designing of

casting process offers in these respects.

Among

the

numerous

illustrations in this

which our engineering department has

is

always at the

Walls

Yir,"

command
and

in

lent valuable aid.

This part of our

some

cases Y^i" thick

and design of the parts and the metals used.

may be cast, depending on the size

The weight in zinc and tin should

not exceed about 10 pounds, in lead about 15 pounds, and

pounds.

The

service

of our customers.

in

aluminum about

average size depends on the piece but seldom exceeds 24" over

Strains and stresses on parts should be studied and

of metal and wall construction.

met by proper thickness

and webs all play a

Inserts, beads, fillets, lugs,

Casting and shrinkage strains occurring

part in the problem.

all.

in

the casting

operation must be considered as well as the comparative die cost of the various
possible designs.

must be perfect and smooth it should always be so

marks made by the pins in ejecting
The casting can usualh' be so placed in the die or the method of
the castings.
ejection so arranged that these marks will not show if proper information is reIf a particular surface

specified, as

almost

all

castings have ejector pin

ceived in the beginning.

Tin alloy. If not die-cast, this part would have to be made of tubing
part.
The tubes would have to be machined, bent, and expanded for the hose
soldered together.
The cost would be many times that of the die-casting which is also more
connections.
accurate and rigid.
Milking machine

42

Magneto breaker

box.

Magneto

housing.

Magnet c
end

plat

GeJierat(
end piec

Tinier

at

rotor.

Gcnerati
dust
cover o)
oiler.

.4!n niiniini

43

and sine

alloys.

Breaker box.

When
in

one

But

piece.

it

may

parts as possible should be combined

sometimes happens that a piece

will be cheaper to split

the part

many

parts are to be assembled as

When

it.

this

desirable

is

is
it

so large or difficult that

be assembled in a simple and inexpensive manner.

Undercuts are the surfaces of

TJnrlpmitS

a part

which,

when formed

would prevent the ejection of the casting

by means of moving parts to permit the part

The

made

is

in the die

die opens at right angles to the parting line of the casting and

be seen that to avoid undercuts the casting must gradually

and below the parting

or irregular surface on a casting

the part

is

is

of

how
may have many undercuts and
undercuts may disappear.

not an undercut, as everything depends on

another position these

in

The methods

forming undercuts

in dies are

The

limited only by the ingenuity of the designer.

usual practice

is

but sometimes

to construct

this

moving

cores or slides,

In such cases

cannot be done.

may

collapsible cores or loose pieces

Such

be used.

construction should, of course, be avoided as

as possible,

as

cores are also

production.

delays

more or

less

much

and expensive

entails delicate

it

and

construction

die

Collapsible

inaccurate, and cannot

They are used to better advanbe properly cooled.

Sand cores
tage in other methods of manufacture.
also

grow smaller above

In one position a part

placed in the die.

by being placed

to pass out.

will readily

must always be remembered that every depression

It

line.

it

in

unless pro-

the die,
vision

it

can always be done so that

They are

have been tried but without success.

inaccurate and the sand gets into the dies and machines, causing considerable trouble.

The

shows proper construc-

tion for fastening lug.

forms an undercut, preventing withdrawal of the

core.

impact of

the metal entering the casting breaks and chips them.

'^harp inside corners should be avoided, as they cause shrinkage cracks

Fillets

and

Metal
around

also

weaken the

at the great speed at

sharp corner as

in the die

part.

and

if

when

which

it is

All such corners should be

it

filleted.

enters the die does not flow as well

rounded.

sharp corner means a knife edge

the slightest surface crack occurs at this point the casting will

break on slight pressure,

in the

same way that the cut of

diamond over

glass

causes the glass to crack.

and functions of the part permit.

Fillets should be as large as the design

When

another part

fits

the edge to be filleted

radius of ^{^o" or ^{;4"

is

it

should be rounded to

sometimes enough for the purpose

if

fit

more

is

the

fillet.

not per-

missible.

Be3.cls

I^eads are used for strength at the ends of tubes or thin surfaces or

around
ing

when

slots or holes.

the castings are

They

are also needed to help

overcome crack-

made.
44

pumps
tin
Assembled pumps shown

Parts of soda fountain

in the center.

45

alloy;

Reinforcement by webs

"^^/'pko

walls,

metal, adding

little

surface of a casting
less

is

are light, are usually only "dead"

The

strength in proportion to weight and expense.

is

chilled

stronger than the inner sections, which are also more or

In considering the design of castings this must be borne

porous.

Heavy

better than by thickening walls.

when other adjacent walls

addition to the other well

known

engineering advantages of

Elbows or Curved Holes ^

^'^'^^^

i" ^

web

in

mind

in

construction.

hl^ presents an undercut

preventing a straight withdrawal of the

core.

It

usual, therefore,

is

when withdrawing
This

shown

the simplest and quickest

is

make

cores in a straight line to

the inside angle of the inner wall of the elbow sharp, as

in the illustration.

method

of produc-

ing such parts and therefore the least expensive.

It

frequently happens that this construction

objectionable and in such case

we

is

can produce almost

any desired design.

tapering turn and also curved inside walls

with no taper at the turn may be cast

as

shown

in

the illustrations.
Simple

elbow

angle bend.

with sharp
undercut.

When

No

withdrawn on an

the core can be

arc not

exceeding about 100 degrees, no loose pieces

die

are needed.

an event the end

In such

which the curved core

is

in the

from

withdrawn cannot have

straight portion at the opening.

Elbow with rounded heiui (undercut). This is formed by a

loose piece held on the ends of the cores in the position
After the cores are withdrawn this piece is knocked
shown.
out of the casting-.

in the middle is formed by a loose core

knocked out after the core in each end has been
This construction requires a substantially inwithdrawn.

The

undercut section

which

is

creasing taper to permit ejection of the loose core.

Curved core withdrawn on an

arc.

46

!?S?

Frame

plates for moving picture machine. Zinc

These plates must be held to extreme
accuracy, as they are used to mount and assemThey illusble the mechanism of the machine.
trate proper use of fillets and iveb construction.
alloys.

47

Outside or

Threads

may

threads

inside

be

cast.

Outside threads

are

usually cast by splitting the die lengthwise across the thread or

forming

in the

it

same manner on

slides.

square thread cannot be cast

way

because

cast

by inserting a bushing with an inside thread

it

This

casting.

One

or

forms an undercut as

is

it

approaches the parting

in the die

line,

but

and turning

slow and troublesome work and should be avoided

two turns

end of a thread.

of the thread should generally be omitted

If the thread

extends

all

way

the

it

to the

end

if

in this

could be
it

off the

possible.

from the open

it

results in a

feather edge on the part as well as in the die, which will easily break or

wear and

interfere with the use of the thread.

Outside threads commonly have an angle of 29 degrees, 55 degrees, or 60

degrees,

and may be held accurate from plus or minus .001"

to plus or

minus

.003", according to size.

Inside threads are cast by turning out the threaded core, but small diameters

and sometimes the larger

lost

sizes

on the casting machine

are to be tapped

it is

in

may
doing

is

to tap

Threads should be made

When

work.

this

totally impractical to

and the universal practice

more cheaply, due to the time

a number of small holes
attempt to cast them with the threads

be machined

them.

as coarse as possible as they are then less likely to

chip in casting and are stronger and

more

accurate.

In casting parts with pipe connections the better practice

and tap

a female thread as

an outside thread

as

shown

shown

in illustration

in illustration

A.

is

to cast a hole

instead of casting a boss with

The wedg-

ing action of a pipe thread exerts a strain which has a

tendency to break such bosses, and the design does not

permit strengthening without shutting
in the boss,

for strength

(^n the other hand as

off the

much metal

opening

ns

needed

can usually be added around an inside

thread which, being larger in diameter than the pipe,

is

considerably stronger anyway.

48

lI'j'CH

Gears operating

Oears

RULE

at high speeds

strain should not be die-cast.

in zinc

is

on each tooth towards the parting

made by

shown

us

to

heavy

also not possible to die-cast gears

and aluminum alloys with the same accuracy

such gears are consequently not as quiet.

gears

under loads subjecting them

It

as they

can be machined, and

Spur gears cannot be

cast

without taper

The few examples

line of the die.

in the illustration will give

of die-cast

an idea of the range of

this

work.

Castings

EnPTavinP"

may

be engraved in any

manner

important considerations must be borne

est

and simplest method

This

engraving

engraved into

and

it,

is

the

The

cheap-

in the die

difficult operation, as

it

it.

on the casting.

to be depressed into the casting as

work

desired but certain

mind.

to engrave the die by sinking letters or designs into

results in raised engraving

If

sive

is

in

must be

raised,

involves cutting

though

which

away

is

it

were directly

sometimes an expen-

the entire surface around

the engraving.

When
ing

may

it is

not desired that the letters project beyond the casting the engrav-

be raised but on a depressed mat.

This

is

simple, as

it

merely involves

inserting a plug in the die.

When

changes of engraving are desired, interchangeable plugs

Engraving may be put on curved or

flat

surface but

it

may

must have plenty

Type-Wheel for CheckProtector.

Letters in right end
alloy.
of part cast depressed to permit

Zinc

filling in

49

with white enamel.

be made.
of taper

Drill Stands.

For the same reason the engraving must be

to prevent chipping of the edges.

very carefully done and the letters polished.

If

ejecting
to be

engraving
it

is

to be put ort

any part of

a casting

forms an undercut and must be made on a

withdrawn before

which rubs the

slide or a core,

the casting leaves the die.

C^learance for Tools

^" machining parts having threads or gears run-

ning into a shoulder or flange

necessary to allow for clearance for the cutting tool.
ings,

however,

it is

it

is

generally

In the design of die-cast-

permissible to extend such threads or gears up to the shoulder

without any intervening recess or groove,

making

die in

which has

as this construction

is

not needed in

the die.

^ *

Number

lu/ieel for

time flock, j" diameter. Tin alloy.

50

Accuracy

VI.
Accuracy
die

is

from

in a die-casting

The

made.

die

is

depends

of all on the accuracy with

first

which

virtually a gauge

fixes the size of

which the

each part cast

it.

The

size

and design of a part and the metal used

Small castings can be held closer than large ones.

Long

also affect
flat

its

castings

accuracy.

warp more.

Castings having an odd and complicated design sometimes shrink irregularly.

Most

of the shrinkage takes place after the castings leave the die.

In large castings the die temperature,

if

operations, as well as the temperatures at

permitted to vary materially between

which the metal

is

cast, will affect the

accuracy of the part.

Precision die-casting machines are particularly well adapted to meet these

They

difficulties.

are so constructed that proper temperature regulation of dies,

machine and metal

stant.

The

is

ing and cooling them,

afFects the flow

Accuracy
gates.

easy.

The

operation of the machine

regular and conmethod of operatkeep casting conditions uniform, which in turn

is

position of the dies on the machine, as well as our

and
is

all

help to

finish of the

metal as well as the shrinkage.

of course also affected by cleaning operations and removal of

This work

therefore given close supervision in our shops.

is

In specifying dimensions the finished or final sizes should be given and no

allowance for shrinkage made, as

those,

however,

who

Lead and

tin alloys

Zinc alloys

Aluminum

this

must be taken care of by us

desire the information

alloys

we

in the die.

about .002" per inch

about .004" per inch
about .007" per inch

Number
51

For

give the shrinkage of our alloys.

nvheels.

which die-castings may be held cannot be

An idea may be formed from the following

Exact tables on the accuracy

given as it varies with each part.
table which, however, for

'.

On

some parts may be too

4" to 8"

.002"

.003"

.0035"

.0015"
.002"

.002"
.003"

.003"
.004"

8" or over

.0035"
.005"

.004"
.006"

line of dies are

more

difficult to

hold to close

almost impossible to keep the die surfaces absolutely clean.

is

air

under high pressure

to clean all particles of dirt

and metal

die surfaces.

The
more

it

compressed

from the

is

liberal:

particular sizes our engineering department's opinion should be secured

because

We use

and for others too

2" to 4"

and permissible limits agreed upon.

Dimensions across the parting
limits,

close

l"to2"
.0015"

O-l"

tin allovs
alloys
Aluminum alloys

Zinc

to

.001"

In dimensions of

Lead and

pressure used in casting also has a tendency to force the dies apart.

in

evidence in large castings

This

under high pressures and cannot always

made

be entirely prevented.

when

In most cases,

necessary,

we

are able to guarantee

work

as close as

.002" to =b .004" across the parting line, according to the casting.

To
parts of

more limited extent there

castings which are formed by
a

particles of metal

home.

less

By

also be a certain
close

amount of inaccuracy in those

moving parts in the dies, as dirt or
slides or cores from going completely

a certain

sometimes prevent the

There must

easy operation.

is

slides or

amount

of

freedom

in

such parts to permit

and careful workmanship, great accuracy may neverthe-

be maintained.

Holes

in

which

a very close

needed,

fit is

i.

e.,

less

than a variation of .001"

We

should be reamed and stock allowed in the casting for this process.

suggest

Holes yi" or less in diameter allow about .004" for reaming

Holes li" to 1" in diameter allow about .006" for reaming
Holes 1" or over in diameter allow about .010" for reaming

When
chining

is

parts are to be ground, about .005" should be allowed, and

when ma-

to be done, about .010".

All holes or walls from which slides or cores must be horizontally withdrawn
or which in ejecting rub die surfaces must be tapered, except in the soft tin and

Without

lead alloys.
crack.

and

When

taper the die will rub the casting, causing

the parts leave the die they are so hot that they are

slight pressure will fracture

As much
allowed as

When
amount

it

it

to chip

still

very

and

frail,

them.

taper as possible (from .005" to .010" or

more per inch) should be

reduces cost by increasing production and also strengthens the parts.

taper

is

of draft with

Hard

objectionable the following table will

which practical

tin and lead alloys

alloys
Aluminum alloys

Zinc

show

the

smallest

results in average cases can be obtained

00025" per inch

0025" per inch
003"
per inch
52

Extreme accuracy

dimension

in ever^'

the time necessarily spent on die work.

is

expensive because

it

greatly increases

Close or particular sizes should therefore

When

be specified and the accuracy to which they must be held agreed upon.
sizes are specified in fractions instead of

more

it

parts are to

gauges, to which
specified,

i,

When
safely,

e.,

we

fit

others not

will work.

whether snug,

the dies are first

generally understood that

making

the

fit

loose,

fit

should be too tight

made by

us, the best practice is to

In such cases the kind of

for parts that

and after the

new

how much

first

must

furnish

desired should be

Pulley ^vheels,

others,

we always work

metal to add to make the

cores or parts in the die

zinc alloys.
Five
speed pulley in

fit

samples are made

the change involves adding metal to the die surface.

center.

fit

loose, or tight.

made

simple matter to determine just

53

is

liberal limits are permissible.

When

the

decimals

would have

it

becomes

fit

right.

to be

made,

a
If
as

.K^_i/

Aluminum magneto
cast in sides

inserts cast in top

VII.
many

In

cases,

when

Cast iron pole pieces

and bottom.

housing.

and laminated

Inserts

the metal of which a part

is

to be die-cast

for certain parts or functions of the die-casting, an insert of

suitable metal or material

may

is

not suitable

some other more

be placed in the die and the metal cast around

it.

Inserts generally increase the cost of castings as the time needed to handle

them

On

in the dies delays production.

difficult pieces

simpler and

less

the other

metals with cheaper ones, in which case the cost

Much

also

which may be
it

hand they may make otherwise

may replace more expensive

troublesome to cast or
is

reduced.

depends on the design of the part and the location of the

so inaccessible in the die that

into the part after

it

is

would be cheaper

it

to drive or

insert,

screw

made.

Subject to rare exceptions, inserts should not be used to strengthen or reenforce a casting by imbedding them entirely in the metal, as for instance

The

practice in concrete construction.

casting by alloying with the surrounding metal.

as

if it

w^ere driven in cold.

to release

its

and

first

the

fall

out

if

It

merely lays

in the

enough of the casting

metal just
is

removed

Consequently the insert really makes the sur-

a given section so

stresses are applied to

tear away, exposing the insert.

without

would

grip on the insert.

rounding walls of
strains

It

is

surface of an insert does not adhere to the

much

smaller and thinner, so that

them they are more

If the strains

when

likely to break or crack

and

could be taken up by the insert

passing through the surrounding walls the case might of course be

different.

Inserts

who wears

must be large enough

to be

handled

easily

by the machine operator,

one and sometimes two gloves on each hand for protection from the

heat.
54

That

part of an insert which

roughened or
depending

Some
posed;

it

in

imbedded
in

part of an insert, sufficient to hold

could not "float" in the

properly.

in the casting

shrinking will hold

should be knurled,
it

in place

without

shrinkage pressure alone.

die, as

then

in the die,

it

its

must always be

they are too large they will not

fit.

If too small,

must

in the dies

rough and have burr^^they will wear away the

If they are

ex-

location could not be controlled.

Pins or studs fitting into a hole

Inserts should be accurate.

fit

is

shaped that the metal

so

If

die.

them

the die will not grip

properly and the inrushing metal will shift them.

Frequently the inserts are so

placed that the dies close upon them.

if

In such cases,

they are too large they

may

seriously injure the die.

It

is

advisable to avoid the use of inserts so placed that the metal will shrink

away from them

instead of to them, as for instance an insert forming the outer

wall of a casting.

Hardened or tempered

num

inserts

may

be used without injury except in alumi-

die-castings.

Inserts are not furnished by us because

wide variety of equipment needed

They can undoubtedly

made bv the customer.

used.

not

to

make

it

would be impractical

the

many

to install the

different kinds of inserts

be bought to better advantage from specialists

if

Zinc tone arm, brass tube

Aluminum magneto

Aluminum magneto

Check protector

pole piece cast

and laminated
hardened
55

insert.

housing.

in.

core.

lever.

Brass

economizer.

Copper

wire

insert.

Aluminum
Threaded

Cross hatch,

steel perforator inserted.

picture machine part.

Gasoline

mesh

Steel shaft

inserts.

Moving
insert.

Iron

optical instrument
brass tube insert.

Zinc ratchet,

steel shaft.

parts.

Bearings and Bushings When

may

or graphite bushings
If thin stock

used

is

be cast
it is

bearing surface to provide

a special

wear

for excessive

is

needed, bronze,

steel,

in.

preferable to cut grooves in the bushings instead of

knurling them, as knurling will spread them, causing them to enlarge.

Oil

holes

afterwards

to

be

drilled

because of the difficulty

possible,

up core pins

of lining
in

inner bushing should

in

when

fit

The

such holes.

delay

production usually amounts to more than the cost

of drilling.

Bushing formed from sheet.

When
in

tice

')iilWiJlJllBlWhiw0JJ^

cheap and effective bushing

up out of sheet brass or

Bushing

Cast

perfectly the better prac-

fit

allow .005" or .010" for reaming after the

to

is

castings are made.

f\

bushings must line up with other parts

an assembly or must

for

drilled

tions.

It

should

be

steel in

may

be formed

one or two opera-

with the seam open

left

as

anchorage.

shown.
Bushings must be accurate and smooth,

to

fit

the dies and prevent excessive

wear.

Studs or Pins

sufficient part of such

posed

properly hold

it

necessary to cut

The

in place.
ofif

inserts

When

the design does not permit this

the insert after the casting

is

left ex-

it

is

sometimes

made.

portion of the insert imbedded in the casting,

more from the surface

must always be

(extending from the casting) to permit the die to

commencing about

jV

"

O''

of the casting, should be knurled, flattened, grooved or

squeezed to provide a better grip.

Provision must always be

having

in

mind

made

in the casting to firmly

anchor the

insert,

the strength and characteristics of the particular die-cast metal

used.

When

studs are cast into a wall the opposite side of which

or finished, a better appearance will be presented

to prevent its

showing through on the surface,

below on the extreme

if

as

is

to be polished

the base of the stud

is

pointed

suggested in the illustration

right.

Methods

of anchoring pins or studs.

56

Plat Snrinp'S

Except

in

aluminum, springs may be inserted without drawSprings are usually anchored by punching

ing the temper.

In some cases eyelets are punched into the holes of the springs to

holes in them.

give a better hold.

Springs .003" to .005" thick should not be over

metal

in

cannot be

be used

cast.

passage for corrosive liquids.

It
It

is

as otherwise the

the design calls for long thin walls w^hich

sometimes used for

may

tubing into which cores cannot be

vent the tube from being

filled

braced with pins or cores

in

made but

when

its

strength, or to afford a

be bent in any shape and used as an

an irregular line through the casting.

sage, following

fitted

It

is

oil pas-

advisable to extend

bayond the surface of the casting to pre-

with metal.

Such tubes must

also usually be

withdrawn when

the die which are

the casting

is

leave holes in the casting up to the outside surface of the tube.

Plates and. PlinchinP'S

^Vhen

flat

plates are inserted

one face only,

the die with cores or pins running to the face

when withdrawn

and perforated

to

leave holes in the casting.

Sheet meral insert, shown

in section of cast-

Frequently used to
form bearing for breaker
box on magnetos.
ing.

it

is

and exposed on

necessary to hold them in

imbedded

permit the metal to grip them.

imbedded

57

wide

shrinking will "pucker" them.

Til hi nO" Tubing may

cores

^"

in the casting.

These

Discs should be countersunk

Die-Casting Processes

VIII.
The

origin of

modern

die-casting practice

of the type-casting machine.'

back as 1838 and were used for lead and

The

may

be traced to the development

Such machines were

built in this

country as far

tin alloys only.

pioneers were Bruce, J. J. Sturgis,

W.

P. Bair, C.

&

B.

H. Dusenberg
it was

In 1885 Mergenthaler brought out his linotype machine and

and others.

which

the ease and precision with

this

machine

cast type that suggested the use of

a similar principle in casting machine parts out of zinc alloys, which have fusing
points ranging only about 200 F. higher than type metals and are

much

stronger

and harder.
It

is

almost a fundamental principle that accurate castings of high fusing

metals cannot be

made

in

commercial quantities without the application of pres-

sure and the use of metal dies.

cast in metal

Steel, iron

and bronzes have for many years been

molds by gravity but not accurately and with sharp

and the

outlines,

castings are limited to simple solid pieces.

The

C^lothiaS Process

French "Clothias" process,

of the

positions are used.

may

between
American application

distinction should here be pointed out

the die-casting process and the

in

These molds are

which various non-metallic molding comfiner

and more substantial than sand and

be used from two to upwards of twenty times, depending on the part cast

The molds are made from patterns and the metal

Each time the mold is used it becomes less accurate and no
moving parts or "permanent" cores may be used. The "Clothias" process, al-

and the accuracy required.

poured by gravity.

though
using

it

it,

is

has been claimed to produce die-castings by at least one manufacturer

merely a refinement of the sand casting process and does not offer the

accuracy or range of the die-casting process.

Note.

Illustrations

and descriptions of various metliods of die-casting

are given in Reference Booiis publislied by "Machinery" (The
Industrial Press, New York City), No. 108 "Die-Casting Machines" and No. 109" Die-Casting Dies, Machines, Methods".
See also "Van Wagner Mfg. Co.'s Die-Casting Practice", 1 and 2,
published in the January and February, 1913, numbers of "Machinery" and articles there referred to.

Compression Chamber

^^^ die-casting processes, as the term

erally understood today,

employ

is

gen-

compres-

chamber in some form, in which the metal is subjected to pressure while

and from which it is forced into metallic dies. This chamber may be
large enough to hold sufficient metal for only one casting or for a great number.
Various methods of applying pressure have been used. Type casting ma-

sion

liquid,

chines employ a piston traveling in a cylinder and this

tory in casting metals melting at 950 F. or

and

is

generally adopted

when

the fusing point

such conditions a plunger cannot be operated.

method has proven

Compressed

less.
is

air

is

satisfac-

widely used

above 950 degrees, as under

In modern dental casting ma58

chines explosive gases are used and in

form

some European processes explosives

of cartridges furnish the necessary pressure.

employed especially

in dental

work by spinning

in the

Centrifugal force has been

the metal chamber and die and

then opening a valve, which permits the metal to rush into the mold.
process

is

slow and can be used only for small parts.

castings but

is

ber

is

not used, but the metal

is

made up

is

Iron piston rings

In this instance a compression cham-

poured into the center of a rapidly revolving die

of steel discs.

Although the plunger construction has proven serviceable

difficulties, especially

when

zinc alloys are used.

the cylinder to secure good compression

pansion and warping.

Sticking

is

which alloy with the

When

out.

If

obtained.

this

iron,

occurs the

pmnp must

is

involves

plungers are well

many

fitted close to

frequently sticks, due to unequal ex-

it

which becomes wedged

sandy mass of oxides and metals

to the cylin-

be removed and the plunger drilled or cut

is

loose, the necessary pressure

they

ers cannot be left at rest in a cylinder for any length of tune

Parts for vending machines.

cannot be

may sometimes, with

become worn too much for use.

fitted

operated as long as a month before they

59

it

plunger

sometimes practically brazing the plunger

on the other hand the plunger

When

If the

also caused by dross

between the plunger and cylinder, forming

der.

This

produces very solid

impractical for general commercial application.

are being successfully cast in this manner.

which

It

Zinc and aluininuin

care,

be

Plung-

and must always

alloys.

be removed

when

the

machine

not in use, as otherwise they will "stick" or solder

is

machined

to the cylinder, necessitating their being

dross excessively, and

it

difficult to

is

out.

with metals that have a tendency to

air is objectionable for use

Compressed

keep tight joints at the temperatures and

These objections can be minimized by ingenuity

temperatures over 950 F. compressed air is thoroughly practical

pressures needed for die-casting.

in design,

and

and

at

efficient if

The

properly applied.

pressure chamber sometimes consists of the entire pot of metal which

covered with an air tight cover and heated with gas or

immersed

in

an open pot

form of a pump or

in the

The

openings below and above the metal.

to the die or die carriage by

from metal

as

means

molten metals and has not been

Cast iron

also used.

is

P'^^'t'""

^"-'*

This requires the use of a valve

In other cases the die

die,
let

connected directly

is

made
at the

almost universally used

attacked more readily by

is

with relation to the pot.

to shut off the

When

is

On

and the die operated under-

raised

the die

metal

pot,

is

when

which

the die

is

also requires a

placed above the level of

considered inadvisable.

It is

upward

into the

no doubt better

to

the gravity assist instead of hinder the casting operation, but the use of valves

many

troubles and objectionable features that

by far the lesser of the two

Except for use

made which

at

nriltinP"

Pots

comparatively low temperatures no valve has yet been

away

in the pot.

molten metal, due

pot of metal

In one case the pot

a casting

is

is

is

tilts.

tilted or a smaller

wear and

the

Either the en-

chamber immersed

mounted on brackets with

the die above

it;

made, pot and die are turned upside down and then the pressure

applied by compressed air in the pot.

It

is

claimed that by this process the

metal enters the dies by gravity and that the pressure

when

to the

the surfaces of the valve.

^" some machines the metal chamber

tire

when

working against gravity

evils.

will operate satisfactorily in

action of the metal in eating

is

neck" having suitable

needed, but then the metal must be forced

which by some authorities

involves so
is

is

is

is

on the side of the

is

valve to retain the metal in the pot.

no valve

Steel

is

be

as satisfactor\

some machines the pot

the pot

may

Pressure chambers must be

of a nozzle.

"""^^ ^'^ ^^"^ ^^ '"

F)lP Position
it.

it

no other known substance will carry the required pressures

for this purpose; malleable iron

removed.

a "goose

pressure chamber

casting temperatures of the metals die-cast.

neath

fuels, or

oil

in the pot

is

only applied

the die and gate are filled with metal, the pressure merely densifying the

casting.

The

fallacy of this

The

into a die by gravity.

out of the gate

in

many

cases.

no amount of pressure will

must be applied

to the

apparent to anyone

is

metal

chills

The moment
fill

the mold.

metal before

it

who

has tried to pour metal

almost instantly and before

the metal chills

To make

it

it

has passed

stops the flow

and

a die-casting the pressure

enters the die and the finish and accuracy of

60

the casting will be largely dependent on the speed with

If the speed of the inrushing metal permits

die.

made otherwise
;

show heavy

the casting will

impression in the die will not completely

and heavy die

and breaking

slow and the metal

is
it

it

which the metal enters the

fill

the die faster than the

body of metal of that shape,

die can chill the outer layers of a

be

to

up, the very thing

fill

in the pot

which

is

ridges,

up.
is

The

good casting can

run marks,

etc.,

and the

revolving of a large pot

pretty well shaken up, atomizing

disclaimed for the process.

It

would

seem that a simpler and more direct method of forcing the metal into the
could be used, with resultant increase in production and

less

wear and

dies

tear on

machinery.

Much
ful

if

it

has been said of the tilting pot or compression chamber, but

has any advantages.

can easily be

filled

Due

being rigid.

but

it

to its

tilting

it is

compression chamber immersed

doubt-

in ^

pot

has no other advantage and has the disadvantage of not

motion tight

air

connections cannot be maintained.

Air

leakage seriously reduces pressures, which of course affects the quality of the
castings.

" ^jp-U

Pots*'

machine widely used has the pot containing molten

metal above the die and the pressure

entire pot.

This requires the use of

a valve,

top of the pot into an opening in the bottom.

and leaks and then

To

avoid

ence

is

this,

it

frequently happens that

which

is

After a
all

applied on the

little

use the valve wears

the metal runs out of the pot.

long bearing surfaces are provided and a certain amount of depend-

placed on the fact that the metal will chill at the gate and act as a plug to

prevent further leakage.

This plug

of chilled metal, however, enters every cast-

ing and in some cases prevents the obtaining of best results

Bracket,
zinc alloy.

Auto ^cashing
de-vice,

aluTnuium.

61

is

a rod passing through the

as a

Bearing cap
Liberty Motor,
aluminum.

matter of

fact,

R. R. s^vitrli
signal part,
zinc alloy.

moving

a large

body of metal suddenly downward much

faster than

can be car-

it

amount of metal suddenly

upward, but on the contrary, the smaller body can be moved upward in a diecasting machine more easily and more rapidly, and in doing so all valves under
moving

ried by gravity has no advantage over

a small

liquid metal are avoided.

Vacuum

from the
asserted that by this

used to exhaust the

process of die-casting

made

such in

is

and

The

means denser castings can be produced.

castings cannot be produced by

in the

is

die cavity just before casting,

obtained have never justified the claims

The

vacuum

^" some processes a

Process

for the

vacuum

it

air

has been

best results

processes.

very nature that absolutely solid

its

All molten metals contain gases which collect

it.

metal and form "blow holes".

These

when metals

gases,

are cast in sand,

are allowed to escape through the pores of the sand while the castings slowly cool.

No

gases can escape through the walls of a metal die and there

We

escape anyway, as the castings chill instantly.

no chance for

is

overcome these conditions

largely by using high grade pure metals and alloys that give off as little gas as

under closely regulated temperatures.

possible

The
cases,

metal enters the die at such velocity that

splashes or sprays in

it

some

permitting gases to escape into the mold and trapping them and air again

almost instantly in chilling.

This can be regulated by the

size, location or direc-

tion of the gate.

In some castings the flow of the metal has a tendency to collect bubbles at

The same

certain points.

around

a sharp corner,

be noticed

when water

is

forced

bubble will cling to the corner no matter

This

the speed of the water.

may

result

is

raj idly

how

great

caused by the change in direction of force, the

heaviest particles of matter being carried the farthest

away from

the corner and

the lightest, being most easily changed in direction, passing nearest the corner.

addition a partial

vacuum

to continue in the

drawn from

same

is

direction,

the water.

rapidly through water; a

into

formed by the tendency of

vacuum

which a certain amount of

It

is

the

air

same condition which

certain points in die-castings, and

by casting into a partial vacuum.

come conditions

it

thing

is

In

the particles of matter

vacuum the air and gases are

when an object is moved
formed directly behind the moving object,

and into

The same

all

is

this

noticed

and gases normally present are drawn.

is
is

It

frequently responsible for "blow holes" at

apparent that the difficulty

is

possible,

of this kind by changing the size

however,

in

is

not overcome

most cases

to over-

and direction of the gate or

its

location.
If the die

is

properly vented and gated, the pressure of the inrushing metal

vacuum is unnecessary. Even if a little

would not be the cause of porosity in a casting. Castings
are made at pressures ranging from about 20 to 70 atmospheres.
In other words,
if
a casting were made in an hermetically sealed die, only about onetwentieth or one-seventieth of the volume of the cavity would be air.
Under

will force out

air

all

the air instantly and a

should stay behind

it

62

ordinary conditions

it

would be impossible

make

to

a casting in a die from which

Therefore the ordinary casting made

less than about 95% of the air has escaped.
with the usual pressure would only contain one-fourth of 1% to one-fourteenth
This would not be suffiof the original air of the die cavity by volume.
of 1

cient to affect the strength of a casting perceptibly as

it

would be

distributed

through the casting.

vacuum

If the

is

moment the metal enters the die, in some

vacuum has a tendency to draw or suck the metal
them and thereby producing a condition much worse than

not shut off the

cases the sucking action of the

to the air vents, sealing
if

To

no vacuum were used.

ance the vacuum

overcome

this,

vacuum

in the die against a

diaphragms have been used

metal chamber, but

in the

prevents the sucking of the metal into the die before pressure

The

compression chamber.

vacuum

is

only

applied to the

the result, and in this no

shown any improvement in product over the approved and

It must also be borne in
processes in which no vacuum is employed.
conditions about a casting machine are such that a high vacuum can not

process has

successful

mind

best evidence after all

is

to bal-

this

that

be maintained due to the heat, chips and

fins,

dust and dirt,

etc.,

constantly pres-

ent.

Die-castings can no doubt be

in

use have

done

in

all

made

most cases

at

ways, and the

in countless

produced a commercial product

many

But

in quantities.

an unnecessarily high cost in time, labor and

processes

has been

it

difficulties en-

countered, and naturally these factors have had a negative influence on the quality
of the product.

T^ip C^arriaP'eS

^^^

"^'^^ ^^'^

mounted on

usually

The

are opened and closed.

a carriage on

carriage

is

which they

usually in the form

two plates to which the dies are bolted and the plates slide on two or four bars.
This carriage is attached to the frame of the machine either rigidly or on a hinge
in such a manner that the dies may be swung away from the nozzle through which

of

the metal passes, to permit ejection of castings and cleaning of the die and nozzle.

The
gles

and

general practice

which are
erally a

is

to

open and close the dies by hand by means of tog-

to hold the die carriage to the nozzle of the

also operated

by hand.

Hand

hand operation.

substantial

enough except

The pumping

in

machine by means of clamps,

plunger machines

operated die carriages cannot be

for very light castings to give the best results,

weight of large dies and the great pressure of the metal entering the
strength and endurance
class labor at this

is

required and

work, except

used to produce good

is

work and

it

much

due

dies.

to the

Great

therefore very difficult to keep high

is

at prohibitive

causes

also gen-

made strong and

wages.

loss

Low

grade labor cannot be

by the production of cracked and

defective castings.

The

difficulty in

applying power to die-casting machine operation has been

the varied character of the dies which had to be used and the necessity of holding
the dies closed under high pressure.

character, for instance,

63

would be

The

mechanical action of a press of any

entirely unsuitable.

It

has been difficult to

adjust casting pressures and speeds mechanically to the requirements of different

dies and it seemed at one time almost impossible to construct a die carriage which

could be operated mechanically and which would not involve too much time and
Power
trouble to adjust it to any die that might in the usual course be used.
driven and automatic machines for use in connection with tin and lead alloys and
for small and comparatively simple parts such as, for instance, type, counter
wheels, and small parts used in connection therewith, have been in use for some

time but are not practical for general use with high fusing metals.

There

Feedinp" Metal into Dies

are

two methods

metal into the

of feeding the

One between

dies.

the

die surfaces, in which case the nozzle through which the metal enters the dies
at the parting line of the dies

ejector side, in

is

which case the nozzle through which the metal enters the

right angles to the parting

is

the other through the lower die-block opposite the

die

is

at

In the latter case a sprue cutter or gate former

line.

needed.

The

gate former

usually a tapered bushing attached to a handle which

is

placed into the die for each operation.

usually on a

cam

It

is

After the casting

of the casting machine.

so as to lift

it

out of the

is

placed between the die and the nozzle

made the gate former is turned

At the same time it breaks off the

is

die.

sprue or gate to permit ejection through the die block.

The

sprue cutter

is

simply a rod or bar which passes through the die into

the opening through w^hich the metal enters the die, called the gate.

casting

is

made

the sprue cutter

impression has been

is

raised free of the gate

sprue cutter

filled the

This

cutting off the flow of metal.

is

When

and the instant the die

pushed into the gate, closing

facilitates the

the

it

and

removal of the sprue from the

and prevents the metal from running out of the die before it sets should the
It also makes it possible to gate through a hole in a casting
or into its side without leaving a gate or sprue on the casting as it comes out of
die

pressure be released.

the die.

A
as they

certain

amount

of skill

must be operated

early or late

may

and experience are needed

at the instant the die

is

filled.

to operate sprue cutters,

fraction of a second

spoil the casting for obvious reasons.

Sprue cutters wear more than cores and are therefore not so accurate when
they are used to form any surface of a casting.

Inasmuch
sure,

as a sprue cutter cuts off the flow of the metal,

and the moment the metal contracts

beneficial effect of the pressure then

and most important of

all,

it

when

also affects

additional metal

contraction in cooling.
difference

is

lost

its

is

it

to

cuts off the pres-

no longer under pressure.

The

on the unsolidified parts of the casting

not possible to feed in metal to

This tends

contraction of the casting.

and spong}' and

is

is

it

make

make up

for the

the center of a heavy part porous

accuracy, as the shrinkage will not be so great

fed into the casting

under pressure

to

make up

for

its

Lighter parts, however, do not show any appreciable

when made with

or without a sprue cutter.

64

Mo-x'i/ig belt

in

Trimming

Room, Fayette-x'i/le

Precision Die-Ca.StinP"

plant.

Precision die-casting machines are the result

of scientific analysis of the causes of defective

riOCcSScS

work and an ingenious application of mapower to replace all hand labor in ma-

chine

chine operation.

We

use both

hand operated and power driven machines,

as

we have found
The

that one type of machines cannot be used with best results for all work.

hand operated machines are used for very light work and their ingenious design
makes the labor light and operation fast. Some castings have been made on these
machines

at the rate of

450 per hour, which means the average operation

of the

machine seven and one-half times per minute.

The power machines

are not automatic in the sense that they

without the direction of an operator, but they are

in the sense that

may

cally perform the various operations required to produce a die-casting

operation of a control lever.

in the elimination of

Their advantage over other machines

heavy labor but

in

the accuracy with

lies

pressure for the metal in entering the dies

fixed

is

which they may be

65

easily

The

Each

proper speed and

determined and when once

constantly maintained by simple adjustments on the machine.

Each machine
ture,

is

by the

not only

adjusted and controlled, and the greater speed and power they develop.
die requires different handling to produce the best results.

be run

they automati-

which

is

is

equipped with a pyrometer which records the metal tempera-

maintained within a limit of 20 degrees.

The

proper temperature

of dies

is

likewise determined and maintained by thermostatic water temperature

No clamps or toggles are used to operate dies, and the die operating
mechanism is very heavy and substantial, remaining rigid and firm under any presThis prevents inaccuracy and cracking of castings due to shifting of dies.
sure.
We have profited by our own mistakes and have tried to learn as much as
No known improvement in modern diepossible from the mistakes of others.
Every detail of our equipcasting practice has been overlooked by our engineers.
ment has been developed with a view to the production of castings of uniform

control.

quality above all other considerations

ered next.

In practice

method which produced

cost

we have found by
the best castings

and speed of production being consid-

close

was

comparison that

in the

in

most cases the

long run also the speediest and

lowest in point of cost.

Special presses for

removing gates

and fins. Trimming

Room, Fayetteville
Planf.

66

Aluminum and

Carburetor parts.

zinc alloys.

Machining Die-Castings

IX.

Making allowance

for the peculiarities of the particular metals used, die-

same

castings are machined the

as other castings.

We

feeds and cutting steels cannot be applied by rule, but

have found that speeds,

amount of experimenting to determine the best practice

Only high speed steels should be used for cutting tools.

certain

steels

in

each case.

in

Machine or

tool

do not hold their edge.

For zinc
and

judgment and

requires

it

alloys cutting speeds should be

from

10%

to

20%

faster than usual,

aluminum from 20% to 40% faster; and feeds about 25% slower.
Tools must be kept sharp. This is one of the most important things to keep

for

Dull

mind.

tools will tear the metal

and forge or spread

Taps and reamers should have

They

it.

comparatively thin walls to crack, due to the wedging action of

will cause

a dull tool.

large flutes to give plenty of

room

for chips

to escape.

Tools should have

chatter, but

num

if

fast

work

at least 5
is

die-castings require

more than

used better results will be secured

angle; that

Tap

is,

This amount

degrees clearance.

required the clearance should be increased.

When

5 degrees clearance.

every other tooth

if

for instance, alternating

is

will avoid

Soft alumi-

an end mill

is

cut back to a sharper

between an angle of 70 and 40.

holes should be from .003" to .005" in diameter larger than for ordinary

work, due

to the

rolling or spreading action of the tap,

thread up to the right

which will bring the

size.

In tapping or reaming parts having thin walls

which will grip the castings

in

such a

way

it

is

best to

make

fixtures

that the walls will be supported against

the spreading action of the tools.

Zinc metals do not require cutting lubricants although

to use them.
67

For aluminum

it is

sometimes better

alloys cutting lubricants should be used.

For zinc

alloys

any good lubricant that will wash out chips and keep the

such as soda water, soap water, turpentine and kerosene

oil,

in

tool cool will do,

equal proportions, lard

For aluminum we recommend a mixture of one part lard oil to three

There are a number of good cutting compounds for aluminum on

etc.

parts benzine.
the market.

In grinding or filing die-castings the wheels or

files

can be kept from becom-

ing filled or clogged with metal to a certain extent by applying tallow or chalk or
both.

file

known

as the

"Vixen" gives better

results than ordinary files

and

grinding wheels are sometimes kept well oiled with ordinary lubricating oil to

prevent the pores from

filling

with metal.

i
Aluminum

'"''Strut

Sockets''

for aeroplanes.

68

X.

Electro Plating Die-Castings

^V^hen a polished surface

PolishinP"

work

very fine

which must be applied with

the surface

Dry emery

it

For

essential.

is

polished with about 150 emery,

is first

mixture of parafine and beef

carbolic acid to kill any germs.

in the castings, so that

required buffing

is

suet,

will tear the surface

prepared with

and imbed

will be impossible to secure a proper finish.

The

itself

surface

only should be touched and care should be taken not to go below the "skin" of the

The

casting.

material.

color with

this,

work, gloves dipped

Long tubular
wavy surface.

down with Tripoli compound or similar

White Acme Compound. In handling fine

then cut

castings are

After

in

whiting should be used.

pieces should be polished lengthwise

Except for the very

finest

and not crosswise

to avoid

work, the emery polishing operation may be

omitted.

The

castings should not be allowed to get so hot that they cannot be held in

the hand, as

will cause

it

Clca.ninP'

^^

'"

them

'^^^

to crack

and will injure the surface of the castings.

must be freed from

processes, the surface of the castings

and

grease, oxides

all

foreign substances.

Dirt and polishing material are sometimes

first

removed with gasoline or

benzine.

The

castings are then

necessary the cleaner

may

immersed

a hot solution

in

less

If

contain about one-half pound of caustic soda to the

gallon, but should never be so hot or strong that

ciable extent,

about 150 F.

at

and the dip should be for

it

attacks the metal to any appre-

few seconds only.

harmful cleaning solutions on the market containing mild

be secured from any well stocked plating supply house.

There

are several

alkalis

which may

good cleaner

is

made

up of one pound of soda ash and about one-quarter ounce cyanide of potassium

to

the gallon of water.

The

caustic cleaners re-act with the grease usually present on all castings,

forming a soap, which goes into solution.

They

base alloys forming zinc oxide and hydrogen.

bath, the pores open
after the casting

is

at

gas.

with the zinc

the metal

and permit some of the caustic solution

is

in zinc

placed in the hot

to enter.

If there-

once plunged into a cold bath, the pores will suddenly close

and trap the cleaning solution, which

hydrogen

also re-act

When

If the casting

is

in time, will act

on the zinc and generate

plated in this condition the gas in attempting to

escape raises the layer of plating, forming blisters which eventually causes the
plate to peel off.
It

is

therefore advisable to

wash out

all salts

before they are trapped in the

pores of the metal by immersing in two changes of clean water of the same tem-

perature as the cleaning bath.

Castings which have been corroded by contact with moisture or liquids forming oxide of zinc on the surface
69

may

first

be cleaned by dipping for a few seconds

water

in a solution of four parts of

one of hydrochloric

to

This solution should

solve the oxide.

of course be cold

which will

acid,

dis-

and the parts should im-

mediately be washed in water of the same temperature before passing through

This operation

other cleaning operations and brushed to color.

the castings are

polished, as surface corrosion

first

is

not used

would be removed

when

sufficiently

by that operation.

Another method

The

bath.

of cleaning

is

with what

is

known

an electric cleaning

as

solution usually contains various alkalies, as carbonate of soda, cyan-

ide, etc.

formula strongly recommended

is

Caustic soda

Yi lb.
Yi lb.

Carbonate of soda

Sodium cyanide

Y2 lb.
1 gal.

Water

In the electric cleaner nascent hydrogen and sodium are liberated at the

The hydrogen

reduces the oxides and the sodium, re-acts with the water,
For
saponifies the grease on the cathode surfaces.
which
forming
150
E.
M.
should
F.
the
bath
be
about
and
temperature
of
the
the
castings
zinc
cathode.

caustic soda,

F. about 6 volts with a high current density.

After the castings have been washed thoroughly

sometimes productive of

it is

Vienna lime, using a soft bristle brush.

in
cold water and they are then ready for
thoroughly
washed
then
he
should
They

better results to rub

them with

a paste of

the plating bath.

Next

PlatinP" Baths

magnesium and aluminum, zinc

to

common

tro-positive of the
is

immersed

in

the

in

black in color and sometimes in a spongy mass.

silver, the

metals usually plated, are

them and zinc there

ence

is

the most elec-

is

When

metallic zinc

an acid solution containing metals electro-negative to

metals are reduced to their metallic state

and

metals.

is

in

consequence

all

form of

it,

those

fine particles, usually

Nickel, cobalt,

tin,

copper, gold,

electro-negative to zinc, and between

This

high difference in potential.

differ-

smaller in an alkaline than in an acid bath.

When

for instance zinc castings are

immersed

instantly occurs before the electric current acts,

on the casting by "immersion"

metallic powder.

in the

form of

in a

nickel bath, a reaction

whereby some

nickel

a black finely divided

Such deposit when coated with grey

nickel, as

is

deposited

non-adherent

sometimes hap-

pens after a substantial black deposit, causes the plating to become loose and peel.

This black deposit usually shows

in the

form

of streaks at such points

on the

casting which have not been subjected to the action of the current.

Attempts

to

overcome

this

by introducing various

salts

the potential between the zinc and nickel have not proven

intended to reduce

satisfactory.

Magne-

sium sulphate has been recommended for the purpose.

The addition of sodium nitrate to the bath is sometimes recommended,

though the function of

this salt

is

al-

not to reduce the difference in potential, but to

retard the chemical deposition of the black

powder on

the zinc,

which

it

does to a

limited extent.
70

Another

sometimes

difficult}'

on zinc, when the parts

arises in plating nickel

The

are irregular in shape, containing hollows or cavities.

the hollows are smaller than on the

more exposed

current densities in

surfaces, giving the nickel a

splendid opportunity' to deposit by immersion and cause black streaks.

The

theory has been advanced that the streaking

While

(black).

is

due

to the

decomposition

an alkaline bath and the generation of nickel sulphate

of nickel sulphide in

may

this

be true in an alkiline bath, the streaking generally

occurs in acid electrolytes, which are the base of most nickel baths.

When

streaking cannot be otherwise overcome,

it

may

be avoided by flashing

or striking the castings in a nickel or copper bath in which deposition by immer-

Such

sion cannot take place.

a bath

is

usually an ordinary plating bath but with

a high alkali content (caustic or cyanide) and a small metal content;

ated at a high voltage, giving the metal very

mersion.

Castings are kept

in this

little

It

low temperature,

a very satisfactory

is

deposition by immersion

it

takes

is

must
place

In this bath the cleaning and plating are simultaneous.

rapidly in a hot solution.

It

since

oper-

This operation

bath for about 20 seconds.

often performed in connection with an electric cleaning bath, in which case

be maintained at

is

opportunity to deposit by im-

method

of securing

good adherent deposits, but involves

the trouble and expense of an extra operation.

In plating zinc as

little free

cyanide as possible should be used to avoid

blis-

tering.

^"

Nickel Ba.th

cases the deposition should be started with an E.

^^^

F. of about 5 or 6 volts
volts.

and then reduced

In doing this care must be taken that the

long enough to burn the work.

Hammond

For

initial

not maintained

direct nickel plating on zinc die-castings

34 oz.
2 oz.

4 oz.
24 oz.

citrate

Water

it

is

boric acid

weakness.

is

gal.

an excellent substitute for the mineral acids on account of

The sodium

citrate retards the deposition

by immersion, although

This bath should

does not alter the difference in potential between the metals.

be kept at

For

or 3

proposes the use of the following bath

Sodium

The

about

voltage

Single nickel sulphate

Nickel chloride
Boric acid

its

2^

M.

to

room temperature.
flat articles

having no recess or hollows, the following bath wnll give

satisfactory results

Double

nickel salts

6 oz.

Single nickel salts

Nickel chloride
Boric acid

Water
Voltage at start 6 volts and gradually reduce
slightly acid with boric acid.
71

oz.

2 oz.
1 oz.
1 gal.

to

about

3.

Keep

the bath

Hammond

Another bath proposed by

for the

same purpose

Water
Another formula which will give good

results

oz.

gal.

Potassium citrate

4 oz.
23 oz.

Ammonium

chloride

Water

The

4
is:

Nickel sulphate

The

is:

16 oz.
2 oz.

Single nickel salts

Nickel chloride
Boric acid

oz.

gal.

usual high voltage at about 5 or 6 to start, reducing at once to about

3.

bath should be kept as nearly neutral as possible to avoid deposition by im-

mersion resulting

in

black spots or streaks.

Caustic potash

may

be added for

this purpose.

All nickel baths should be as near the neutral point as possible,

should not be strongly acid or alkaline.

boric acid should be added until

If

becomes slightly

it

e.,

i.

the}'

the solution becomes too alkaline,

becomes

If the solution

acid.

too acid sufficient caustic potash to overcome this should be added.

Over

acidity

will cause black spots or streaks, the result of deposition by immersion.

Brass Ba.th

l^'''iss is

deposited in the same

The

tion of zinc salts.

making

the proportions used in

equivalents of the two metals,

The

color

may

alloys,
i.

be deepened or

e.,

manner

as copper,

with the addi-

ratio of zinc to copper should not be in

but rather

proportion of the chemical

in the

63^2 parts of copper and 3212 parts of zinc.

made

lighter by reducing or increasing the zinc

content.

good formula

is

Copper cyanide

4 oz.
4 oz.
Q. S.

Zinc cyanide
Soda or potassium

Water

gal.

Slight excess above that necessary to dissolve zinc

and copper.

Anodes

of rolled brass should be used with an

of the area to be plated.

ture.

E.

M.

There should always be

anode surface always

F. about 5 volts, best

sufficient free cyanide

anodes clean and free from slime, for which purpose

which should be kept

Temperature:

as

low

worked

in

in excess

room tempera-

the bath to keep the

in

very small excess

is

needed,

as possible.

Either room temperature or higher.

Another bath recommended

is

Sodium carbonate
Sodium bisulphate
Copper cyanide

4 oz.
3

Zinc cyanide
Potassium or sodium Q.

to clean

S.

and

oz.

2 oz.
2 oz.
slight

excess.

Water

CoDDCr

Ba.th

gal.

Castings are seldom copper plated for finish but

done

as a base for

it is

usually

another deposit or to protect castings

from corrosion, which may be done by a copper "strike" or "starting" bath

pre72

For

viously described.

formula

direct copper plating an alkaline bath

best.

is

good

is:

Copper cyanide
Sodium or potassium Q.

4 oz.
S.

with slight excess.

Water

gal.

Potassium or sodium carbonate

is

recommended

usually

in

such baths but

it

unnecessary because some of the excess sodium cyanide, being exposed to the

is

surface,

Too much

converted to carbonate.

is

harmful and

it

is

sodium cyanide

of an excess of

is

therefore better to have a small excess and replenish the bath

occasionally.

Best results are obtained with cast anodes; they should be cleaned and

scrubbed occasionally to remove the slime,

Keep bath

tivity of the bath.

with

about

initial of

at

vv^hich

materially weakens the conduc-

room temperature; E.

M.

F. 2^2 to 3 volts,

5.

After the castings have been "struck"

in copper,

other finishes

may

be applied

according to general plating practice.

X*in

"^"^^ castings

Bath

should receive the same treatment for cleaning

Copper

nickel plating.

done

in

an electric cleaning bath.

Wash

in

phosphate bath as follows

Sodium pyrophosphate

10 oz.

Stannous chloride (fused)

Water

6 gal.

The bath should be maintained at room

The tin salts are difficult to dissolve in

volts.

best

method

is

to enclose

moved

the surface and

Cast

tin

to

as for

20 seconds, which may be

cold water and then place in pyro-

strike for 15 or

oz.

temperature; E.

M.

F. about 3;!/

the pyro-solution and therefore the

them in a muslin bag which should be hung

and fro frequently.

anodes of the highest quality should be used, but the

tin

just

below

content will

not remain constant as the anode dissolves at a lower rate than deposition takes
place.

Tin should

therefore be added periodically by adding solution or hanging

bag of stannous chloride

low

bath

is its

Soc.

29 (1916)

in the bath.

An

bath highly recommended by

to this

Mather

& Cockrum

(trans) Electro.

Chem.

is:

5%
6%

Stannous oxalate

Ammonium

oxalate

1^%

Oxalic acid
Peptone
Balance water.

Reduced

made

objection which has been

tin content.

i%

to the English system the

formula will be

Stannous oxalate

Ammonium

oxalate

Oxalic acid
Peptone

This bath

is

8 oz.
2 oz.

Ys oz.
1 gal.

Water
said to give firm, thick

tage of a higher tin content.

7 oz.

and smooth deposits and has the advan-

Stannous oxalate must nevertheless be added per-

iodically to maintain the tin content of the electrolyte at the proper proportion.
73

The

RatH

Silvfr

casting should be cleaned in the usual waj' and then

flashed in a silver striking bath as follows:

The

8 oz.

Water

which they may be placed

preliminary plating or coating

which will cause

sion,

oz.

Sodium cyanide

gal.

castings should be left in this solution 15 or 20 seconds at a voltage of

5 or 6, after

cyanide

Silver

in the silver bath.

is

needed to prevent deposition by immer-

peeling.

may

In place of the silver strike a copper or nickel strike

be used but the

not advisable when a very thin silver coating is to be given, as the color
The castings are then, after washing, dipped in a mercury
will show through.

copper

is

bath as follow^s

Red oxide

of mercury
Potassium or sodium cyanide

Water

The immersion
of

oz.

8 oz.
3 qts.

should

about 5 or 6 seconds,

last

mercury will be formed which will make the

desired to reduce the expense of plating as

much

in

which time

a thin film

When

it is

as possible, the striking bath

may

silver

adhere better.

be omitted and the articles merely quickened in the mercury dip before silver plat-

They may

ing.

be immersed in the silver bath after the dip without rinsing in

water.

The

Q.

silver bath

22 oz.
Q. S.

Water

gal.

Sufficient to convert the silver nitrate to the double cyanide (solution

S.

of the cyanide)

cyanide.

is

Cyanide of silver
Sodium cyanide

and an excess of about one (1) ounce of sodium or potassium

is needed to convert the silver cyanide which forms at the

This excess

anode into the double cyanide.

If this

rounded with an insoluble crust of

is

not affected, the anode will become sur-

silver cyanide,

which increases the resistance

to

the current.
Sufficient cyanide should be constantly

added

to

keep the anode free from

slime and dirt.

Use
duced

to

Gold

Initial voltage of

rolled silver anodes.

2y2

Room

to 3.

Ba.th

which should be

good lustre maintained on the surface.

wasteful to deposit gold directly

absorbed

in the castings.

the gold,

making

it

6,

re-

castings should first be well coated with copper or brass

"""'^^

and

about

temperature.

The

It

would be very
would be

on zinc as a good deal of the deposit

copper or brass finish furnishes a background for

possible to secure good results with a comparatively light de-

posit.

The

ordinary bath

is

Gold cyanide

oz.

Water

gal.

Sodium or potassium cyanide

Q.

S.

74

Q.

The
Too much

and clear the solution.

Sufficient to dissolve the gold cyanide

S.

cyanide should be kept low, just enough to keep the anodes clear.

Use anodes

cjanide will produce a pale, dirty color.

keep the gold content

Maintain bath

down

in the

as little as one-third

potassium cyanide

is

becomes 3'ellowish and "brassy"

If the color

the solution by adding gold cyanide dissolved with

E.

M.

The

sodium or

F. about 3 volts.

recommended

also

is

oz.

ij oz.
6
6

Water

silver

also be used.

ounce can be used and the temperature kept at 150 F.

not advisable.

following formula

M.

may

desired to keep the gold content

Phosphate of soda
Sulphide of soda
Sodium cyanide
Chloride of gold

E.

of fine gold rolled thin to

sheet of carbon

room temperature, but when

High temperature
add more gold to

The

A thin

bath down.

penny wt.
pennywt.
gal.

F. about 2y2 volts at about 160 degrees Fahrenheit.

casting should be protected with the usual "banana oil" lacquers for the

and gold

when

finishes

The

possible.

cotton dissolved in amyl acetate.

base of these lacquers

is

usually gun

good coach varnish may also be used, thinned

with turpentine or benzine.

Aluminum

Aluminum

Polishinp*

is

which have

The

very

much harder

parts are sometimes

will take a very high polish.

This

especially true of alimiinum-copper alloys,

surface than pure aluminum.

dipped

first

in a dilute solution of caustic

potash and

then thoroughly rinsed and dried.

The

polish should be free

from

grit

applied on a rag or felt wheel with glue.

stone and

oil

The

and

Nos. 120-150 emery

alkali.

The

is

used

parts are then buffed with pumice

or rouge.

polish will be retained as well as

on

silver but

must

of course be kept

bright and clean and given the same attention as other metals.

PicklinP"

^^

Aluminum

remove

substances

soda saturated with

common

salt

is

This will give

KleCtrO-PlatinP"
.

i~\.l

UllllUUm

takes place in the

Another

oxide and other

solution

cooking

of

a color

resembling matted

less difficulty,

aluminum

due

is

to

20

in run-

silver.

attendant with

to its being highly electro-

positive to all the baser metals (including zinc) except

magnesium, and deposition by immersion therefore

same manner as described with zinc castings.
(See p. 70).

difficulty

is

that

stantly on exposure to oxygen,

surface of the parts.

75

10%

fat,

20 seconds, then washed well

'^^^ electro plating of

more or

hot

sometimes used and parts dipped for 15

seconds, then brushed and dipped again for

ning water and dried.

particles of

aluminum becomes coated with

a film of

oxide

which prevents the deposit from adhering

in-

to the

used.

These difficulties are somewhat eliminated when copper-aluminum alloys are

Metals containing 8% to 18% of copper, balance aluminum, can be given

a good adherent deposit.

following method of plating aluminum

The

recommended

is

the Brass

in

JVorld oi May, 1907:

Clean the

article

from grease and

dirt in the usual

pickle of hydrofluoric acid, then "quicken" in a

and again place

now

in

the hydrofluoric pickle imtil

way and

mercury bath

then dip in a
for a

commences

it

ready to be copper plated or silver plated before

it is

5%

few seconds

to bubble.

The

nickeled.

It

is

copper

bath should be about 150 F.

A
French
cally

new method

of nickel plating

scientific journal.

forming an

It

alio}' of

can (like sheet metals)

is

is

the subject of a patent described in a

claimed the deposit

aluminum and

is

firm and adherent, practi-

It will

nickel.

hammering and

stand

be bent without cracking the plating, according to the

authority.

The

parts are thoroughly cleaned

first in

a bath of boiling potash to

grease and are then scrubbed with milk of lime.

bath of

2%

parts of hydrochloric acid,

this dip until

it

metal

M.

The

500 parts water and 1

what the inventor

is

now

is

carefully

is

made

part

calls

is

of

in a

500

kept in

"metalling

washed

in

water.

ready for the nickel bath, proposed as follows:

1

Nichel chloride
Boric acid

E.

a bath

takes on an appearance of

Water

An

is

Next

part iron.

After each of these operations the part

watering".

The

This

potassium cyanide for several minutes.

remove

followed by soaking

F. of 2>2 volts

gal.

7 oz.
3

is

used.

The

oz.

plate takes a high lustre on polish-

ing.

Note.

See

"Nickel Plating Cast or Sheet Aluminum," Metal Industry

for January, 1919, page 25.

Aluminum "Jane"
for aerial bombs.

76

XI. Lacquers, Enamels and Chemical

Finishes
All metal parts before the application of any finish must be thoroughly
cleaned and

come

all

in direct

foreign matter

ings for electro-plating baths

washed

removed from the surface,

may

perature as the cleaning bath, then washed

then thoroughly dried
ishes

which are apt

if

water

in

in

is

All

fin-

corrode or which are easily brushed or worn ofi

dissolving about

good lacquer com-

oz. of cellulose nitrate in about a quart

mixed with

of amylacitate and thinning the mixture with grain alcohol

Some add
As a

be

water of the same tem-

enamels, lacquers or paints are to be applied.

to discolor or

made by

may

room temperature, and

at

should be protected with a good metal lacquer or varnish.

monly used

permit the coating to

be followed (see p. 69) or the castings

which the parts should be thoroughly rinsed

used, after

to

usual methods of cleaning die-cast-

Gold-Dust, Oakite or any mild cleanser may be

hot soapy solutions.

in

The

contact with the metal.

ether.

fusil oil to the amylacitate.

rule lacquers can be

bought

to better

advantage prepared according

to

requirements from responsible manufacturers.

El

Cold LaCQlierS and

namels

After cleaning, the parts

an

may

if

and

is

also

a filler

is

first

applied.

The

filler

gives the

more adherent, thereby making the enamel

usuall}' takes

may

richer

tone

The

filler

is

generally

first

about one-half to two hours,

This will dry

in

according to the material used.

Materials for

this finish

and

stick better.

be applied.

several of the larger paint manufacturers

enamels

Best results are

work

about half an hour to dry and the enamel, which

thinned down,

r
u
L-old

^
which need not. kbe kbaked.

els,

usually have a celluloid base.

obtained

be sprayed with

brush or dipped with lacquers and enam-

air

a list of

may

be secured from

names will gladly be

fur-

nished on request.

Ena.mcl

Ba.k.cd

I^'^'^^d

enamel

is

applied to die-castings in the same

ner as to other metals.

the castings

must not be heated

which will bake

to

In

all cases

man-

except aluminum,

more than about 250 degrees F. Enamels

temperature may be secured from standard

satisfactorily at this

paint concerns.

IVleta.1

Finishes

A^^^^' being cleaned the parts

num, bronze, or gold

used for this purpose, giving any desired
suitable carrying liquid, either a

The

coach varnish

is

The powders

preferable for interior work.

ing and will not crack or peel.

be coated with alumi-

Metallic powders are

good light coach varnish or

be thinned with turpentine or benzine.

77

finish.

may

lacquers.

are

mixed with

metal lacquer.

Before using

For exterior work lacquer

is

it

should

more

last-

Rlark

Aluminum,

Kim'sll

zinc and

finish similar to

Antimony Dip

other alloys

to

2%

86 to

87%

'

immersed

till

well coated with a deep black powder and

then thoroughly rinsed in clean water and dried, preferably with hot
black powder should then be brushed or very lightly buffed

The

Coloring

Aluminum

in time.

According

to a patented process

No. 1023291, issued

the

to S.

be durably finished in colors ranging from steel grey to

black,

The

air.

off.

parts should then be coated with coach varnish or transparent lacquer, as

otherwise the finish will come off

may

foUow-

12%

Hydrochloric acid

parts should be

be given

in the

ing solution, after being cleansed:

Antimonv chloride
Water

The

may

gun metal by dipping

depending on the temperature

aluminum

is

at

which the work

is

(U.

S.

patent

Axelrod) aluminum

brown and

done.

The

finally to

surface of

treated with a solution of cobaltous nitrate maintained either

The parts are then heated by muffle or blow pipe.

low temperature wmII color it steel grey and as the heat is increased the color
deepens to brown and finally to black.
It is claimed the black will not wear off

neutral or slightly alkaline.

by

in

friction.

Aluminum may also be coated a brown color of different shades by dipping

ammonium solutions which attack the surface, forming a coating more resistant

than the natural metal.

This coating, although attacked rapidly by concentrated

from air and moisture as well as from

acid or alkaline solutions, resists corrosion

dilute mineral

Black

and organic

acids.

Oxidizinp"

*^^^P

black finish

may

be secured by

plating the parts in the usual

them

in a solution of liver of

sulphur.

first

This

finish

copper

then dipping

If desired, portions of the parts

be buffed, exposing the copper background.

a

way and

may

then

should be protected with

good coat of lacquer or varnish.

Note.

very comprehensive article on chemical finishes appears

American Machinist,

issues of April 27

and

May

in

18, 1911.

78

Soldering Die-Castings

XII.

^^"^ "^ ^^^ chief reasons difficulty has sometimes been encoun-

7\r\C AlloVS

tered in soldering zinc die-castings

coating of
zinc

is

aluminum oxide on

when

high, causing the solder to chill

from alloying with the zinc.

It

is

the formation of a fine

The

the die-cast surface.

heat conductivit.v of

applied and thereby preventing

it

metal over about

also necessary not to heat the

is

275 F.

Any low

fusing solder

may

be used (see Solder Alloys,

solder of almost the same hardness and color of the zinc alloys

Zinc
If

is

not desired the following formula

may

Tin

s%

Aluminum

flux should be used.

The

around the soldering

as a "flux"

may

We

but

it is

acid

joint.

a little

if

20%)

suggest a solution of zinc chloride (about

with a few drops of hydrochloric (muriatic)

salt in solution.

be used:

15%
841%

Zinc

acidified

good

composed of

50%
30%
20%

Cadmium
Tin

cadmium

87).

p.
is

keep the

acid, sufficient to

not removed will discolor and corrode the metal

If this

more

objectionable,

is

difficult to

handle.

powdered

To

rosin

overcome

may

be used

this the rosin

be dissolved in alcohol.

The

solder should be well rubbed into the casting before

to alloy with the zinc.

If possible the

it

chills to

permit

it

parts to be soldered should be rubbed

against each other and heated sufficiently to keep the solder liquid while this

is

done.

The
may

castings after being fluxed are sometimes dipped in molten solder

be kept in a small pot over a

low

flame.

Care should be taken not

heat the solder, which causes a volatilization of the metals.

coated with a film of oxide, clean

with

it

a pinch of

If the solder

which

to over-

becomes

sal-ammoniac.

After the parts are dipped they are assembled under the heat of a small torch.
If

notwithstanding the instructions here given peculiar conditions existing

any particular case cause trouble,

made up

may prove

it

of a saturated solution of mercuric chloride, to

drops hydrochloric acid to every ounce of solution.

making

Low

Aluminum

as

heats.

creased to

will not alloy with solders at

because

it

is

maintain the proper soldering temperature

such an excellent conductor of heat.

veying the heat rapidly

ture at that point
79

acts as a binder

temperature solders should not be used

aluminum

Ordinary solders alloy with copper at about 450

about 650 F. in the case of aluminum.

It is difficult to

num

which may be added

The mercury

the solder adhere to the part.

SolderinP"
low

in

helpful to use a mercuric flux,

away from

in

F.,

which

is

in-

working alumi-

The aluminum

by con-

the point to be soldered reduces the tempera-

below that needed

to

properly alloy the solder with the part.

It

frequently said that

is

This

"greasy" surface.
to the

same

is

difficult

Aluminum on

effect in prmciple.

becomes coated with a

coming

aluminum

with the metal.

it

has a

nevertheless

is

being exposed to the

instantly

air,

which prevents the solder from

fine invisible film of oxide,

in direct contact

to solder because

a misconception, but the chief trouble

is

In order to secure a good joint,

it

is

therefore necessary to secure a clean surface by removing this coating.

When

metals other than aluminum are to be soldered,

with fluxes or soldering

from the surface

the oxide

No

it

is

aluminum has been found.

of

flux should therefore be used except such cleaning fluids as

to clean the surface of dirt

aluminum

surface, but after

Aluminum

easy to do this

but no satisfactory chemical method of removing

salts,

This only applies

and grease.

may

be needed

to the tinning of the

has been tinned the usual fluxes should be used.

it

should be soldered by heating

to

it

about 650 F. and rubbing

the solder into the surface of the metal with a stick of solder, or with a blunt in-

In this manner the oxide film will be mixed into

strument or brass wire brush.

the solder and the solder permitted to

any

air

come

can touch the aluminum surface.

in direct

The

oughly and care taken that during the operation

the surface

The

is

"tinned"

best

dering iron

is

method

it

may

The

of applying the heat

not as satisfactory.

chief ingredients in

it

remains perfectly liquid. After

be soldered to other parts in the usual way.

the care and thoroughness with

in small

contact with the part before

solder must be rubbed in thor-

The

is

by blast lamp or blow pipe.

which the solder

aluminum

A solupon

durability of the joint will depend

is

"rubbed

in".

Other metals

solders are tin and zinc.

proportions are frequently recommended in addition, but their utility has

not been demonstrated.

Among

these are

cadmium, bismuth,

lead, copper

and

nickel.

The most

widely used and no doubt an excellent formula

1892 by Joseph Richards and generally known

Phosphor
Tin

is

is

It

is

tough and very nearly the color of aluminum.

not practical to

make

It contains

not desired or available one part of aluminum

must be put where

that patented in

part
29 parts
11 parts

tin

Zinc

This metal

is

as Richards' solder.

solder flow into

If

may be substituted.
an aluminum joint.

phosphor

The

tin

solder

wanted by "tinning" the parts first. After being prepared

the parts are held together and heated sufficiently to make the solder fluid and
then they may be chilled by plunging in water.
Care must be taken to permit
the joint to set and it should not be moved while the solder is fluid.
A soldered aluminum joint will not hold under water or in moist air and all
such joints should be painted, varnished or coated to protect them from corrosion.
As has been previously pointed out, metals corrode and disintegrate rapidly
it is

moisture when in contact with other metals electro-negative to

Tin and zinc are electro-negative to aluminum, but no better elements
soldering aluminum have been found.
Note. An instructive article, "Solders for Aluminum," will be found in

in the presence of

them.
for

Metal Industry for November, 1918. Copy of this article can

be secured from the Bureau of Standards, Washington, D. C.

the

80

WeldinP"

Aluminum

^^^
may

commercial processes of welding

different

with

skill

and experience be applied

to

aluminum die-castings in many cases. A very interesting article to those wishing

more detailed information, by Paul D. Merica, appears in the September, 1918,
issue of the Metal Record and Electroplater, under the title "Aluminum and Its
Light Alloys." The same article is published by the Bureau of Standards, Washington, D. C. (Circulars 76 and 78), and may be had on application.
In general, soldering is preferable to welding except where special strength
in the joint is required or where the parts will be exposed to moisture or water and
can not be satisfactorily coated or painted.

As

previously explained, the electro-

negative metals in the solders tend to cause disintegration in the joint in the pres-

ence of moisture, but as no metals electro-negative to aluminum need be used in

welding, welded joints are more lasting under such conditions.

Care must be used

in

preheating the parts for welding.

permanently weaken and warp the metal and cause

be
to

made with sawdust, the danger

char quickly.
At the right heat

Cements

it

point being reached

it

Too much

to sweat.

will char slightly

when

good

heat will
test

may

the sawdust begins

and slowly.

Metal cements may on occasion be used to advantage instead of

more troublesome and expensive process of soldering. When

the
little

or no strain

When

is

put on the joint make up a putty of glycerine and lead oxide.

greater strength

is

required,

oxide to the consistency of a putty.

mix sodium

silicate

(water glass) with zinc

After application dry for about 24 hours and

then heat to about 150 F. for a short while.

very complete article on plastic cements with formulas

the Brass

World and

Platers Guide for

May,

may

be found in

1917.

Fire extinguisher part,

Antimonial lead.

i^
"*9l^

81

TABLES

PRECISION ALLOYS
During a period of over eleven years we have made and thoroughly tried
hundreds of white metal alloys and made accurate observation of their qualities

when new and

The

after service for extended periods.

formulas given below have survived a process of elimination which has

been thorough and

rigid.

In strength and service they completely cover the usual

requirements of die-cast parts of

may

justify a modification

recommendations that will

and

all

kinds.

in

suit the

purpose

limitations of the die-casting process.

Symbol

In rare cases very special requirements

such cases our laboratory will gladly

if

it

is

make

possible to do so within the

USEFUL INFORMATION
To

convert degrees Fahrenheit (F.) into Centigrade (C.) subtract 32, mulremainder by 5 and divide by 9. To turn Centigrade into Fahrenheit,
multiply the number of degrees by 9, divide by 5 and add 32.
In the Reauner scale used in France 5 C. equal 4 R.
tiply the

One H.

ute.

P. expressed in heat units

British

temperature of

778

lbs.

ft.

33000

-^^

Thermal Unit (B. T. U.)

lb.

One

of water at or near

lb. of fuel

2,545 heat units per lb of

per

H.

is

42.416 heat units per min-

the heat required to raise the

39 F. one degree F.

P.

1,980,000

One
per

lbs.

ft.

fuel.

Circumference of circle := diameter X 3.1416

:= circumference X 0.3183
Diameter of circle
Area of circle
square of diameter X 0.7854
Length of arc
number of degrees X diameter

^
^

To

B. T, U. r=
of fuel or

lb.

0.008727

find the area of a triangle, multiply the base by one-half the perpendicu-

lar height.

To

find the area of a trapezoid,

tiply the

sum by

add the two parallel

sides together

and mul-

half the perpendicular distance betw^een them.

To find the area of a regular octagon, multiply the square of the diameter of
the inscribed circle by the decimal .828.
To

find the area of a regular hexagon, multiply the square of the diameter

of the inscribed circle by the decimal .866.

A gallon of water (U. S. Stand.) weighs 8g lbs. and contains 231 cu. in.
A cu. of water contains 7.48052 U. S. gal., weighs 62.47 lbs. at 32 F.
ft.

To

find the pressure in lbs. per square inch of a

column

of water, multiply

the height in feet by .434.

Atmospheric

air pressure at sea level

Specific gravity

is

14.7 lbs. per square inch.

weight of a body compared with the weight of an equal

bulk of water.

To find specific gravity. Divide the weight in air by the difference between
the weight in air and submerged in water.
GAUGES FOR VARIOUS MATERIALS*
The gauges by which various metals are ordered and

sold are not standardized and one metal

It is safest in ordering to always specify the gauge, but a
be ordered in a variety of gauges.
way and one which is gradually gaining ground, is ordering by decimal parts of an inch.
The following table gives the gauges which are most usually used for a variety of materials, but,
as before stated, the gauge shouM be specified in ordering.

may

better

still

Material
Tubing

Steel

Gauge
U.

Seamless Brass Tubing

Seamless Copper Tubing

Wire

Steel

U.

Brass Wire

Wire
Wire

Copper
Iron

S. S.

Stubs
Stubs
S. S.

Stubs
B.

U.

&

S.
S. S.

Material

Gauge

Sheet Iron
Sheet Aluminum
Sheet Steel

U.

Manganese Bronze Sheets

Brass Sheets
Copper Sheetsi
Steel

Rods

Tin

Plate2.

S. S.
& S.
S. S.
B. & S.
B. & S.

B.

U.

Stubs

U.

1 Copper sheets are also gauged by the weight in ounces per square foot and in the
sheets in pounds per sheet 30 x 60 inches.

S. S.

heavier

2 Tin plate is gauged by the weight of a basic box which contains 112 sheets each 14x20
This rule holds up to 100 lb. basis.
The terms IC, IX, 2X, 3X, etc., are used for the
heavier gauges, these terms designating plates weighting a certain number of pounds per basis box.

inches.

*Data furnished by U. T. Hungerford Brass & Copper Co.,

& Co., and others.

J.

M. &

L. A. Osborn Co., Carter,

D'onlevy

84

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ELECTRO CHEMICAL SERIES

("Weichmann" Notes on Chemistry)
1

Caesium

45
46
47
48
49
50

Silicon

Titanium
Columbian

Tantalum
Tellurium

52

Antimony
Carbon
Boron

53

Tungsten

54

Molybdenu
Vanadium
Chromium

51

55

56
57 Arsenic
58
59

Phosphorus
Selenium

60 Iodine
61

Bromine

62 Chlorine
63 Fluorine

64 Nitrogen
65 Sulphur
66 Oxygen

to all the

elements which

METRIC CONVERSION TABLES

Note.

Abbreviations:
Kilometer,

Ton, M. T.

= 10

Cm.

Metric ton

Mm.

Millimeter,

Mm.

Gramme, G.

Km.

Centimeter, Cm. Meter, M.

Kilogram, Kilo, or Kg. Metric

Cubic Centimeter, C. C.
1

= 1000

M.

Kg.

100
1

L.

Cm.

= 1000

Km.

Liter, L.

= 1000

M.

Kg.

= 1000

G.

C. C.

A liter of water weighs a kilo and contains a cubic decimeter in volume.

A U. S. gallon contains 231 cubic inches and weighs 8.345 lbs. of water

at

62 F. The English gallon correspondingly weighs 10.017 lbs. and contairrs

277.27 cubic inches. An English gallon contains 4.54346 L. and is the equivalent
of 1.20032 U. S. gallons.

The

following table gives only the denominations

in practical

and general

A FEW LOW FUSING ALLOYS AND SOLDERS

CO-EFFICIENTS OF FRICTION
The

relative value of different materials of construction ascertained as the

made by

result of tests

the National

Brake

&

Clutch

Company

is

tabulated as

follows
Materials

Co-efficient

Metal and cork

Leather and cork [ on dry metal
Fibre and cork
Metal and cork
Leather and cork
on oily metal
Fibre and cork
J
Fibre on dry metal
)

0.35

}-

0.32

Fibre on oily metal

0.27
0.10
0.23

Leather on dry metal

Leather on oily metal
Charred leather on oily metal
Metal on dry metal
Metal on oilv metal

The

co-efficient

will

0.15
0.08
0.15
0.07

vary with the condition of the contacting surfaces.

Smooth and unyielding surfaces

offer less resistance than

rough and yielding ones.

In metal to metal contacts different metals are usually employed for the opposing
surfaces, as bronze

and

steel in plate clutches

and

and

cast iron

steel in

brakes of

the shoe type.

WEIGHTS AND MEASURES

TROY WEIGHT

=
^
ounces =

20 grains
20 pwts.
12

CIRCULAR MEASURE
60
60
30
90

ounce
1 pound.

APOTHECARIES WEIGHT
20 grains ^=. 1 scruple.
3 scruples -^=. 1 dram.
8 drams
1 ounce.
12

=
^

ounces

The ounce and the pound

same as in troy weight.

in

this

are

AVOIRDUPOIS WEIGHT

^ dram.
16 drams =
ounce.
16 ounces ^
pound.
25 pounds =
quarter.
4 quarters
cwt.
short
2,000
27gi grains

4 pecks

12 inches
1
3 feet
iV2 yards

quart.
1 peck.
1 bushel.

^
^
= chaldron.

4
2

pint.

barrel.

640

TIME MEASURE

days

week.
days
days
(30
1

month
computing
365 days
366 days

minute.

=
^

^
calendar
= month

interest).
year.
leap year.

sq.

ft.

sq.

sq.

CUBIC MEASURE

1 hour.
day.

28, 29, 30 or 31

=
=
yd.
=
^ rood. rod.
acre.
roods ^
acres ^
square mile.

1
sq. ft.
3054 sq- yds.
40 sq. rods

^
=

sta.

60 seconds
60 minutes
24 hours ==

144 sq. inches

foot.

SQUARE MEASURE

^=
quart.
gallon.
quarts =
gallons =
hogshead.
barrels ^

31 >1

^
^

8
3

LIQUID MEASURE
1

rods

^ yard.
=furlong.
rod.
rods =
mile.
furlongs ^
miles ^
league.

40

36 bushels

4 gills
2 pints

sq.

LONG MEASURE

ton.

DRV MEASURE
2 pints :=:
8 tjuarts

=
^

7.92 inches
1
link.
25 links
1
rod.
4 rods
1
chain.
10 sq. chains or 160
1
acre.

640 acres
1 square mile.
36 sq. miles (6 miles square)
1
township.

lbs.

the

^=-

360

SURVEVOR'S MEASURE

pound.

=
^
=
^

seconds
1 minute.
minutes ;= 1 degree.
degrees
1
sign.
degrees
1
quadrant.
4 quadrants := 12 signs, or
degrees
1
circle.

pwt.

in

1,728 cubic
21 cubic ft.

in.

cu.

ft.

cubic yd.
1
128 cu. ft. =;: 1 cord (wood)
(shpg).
40 cu. ft.
1 ton
standard bushel.
1
2,150.42 cu. in.
standard gallon.
1
231 cu. in.
1
about .8 of a bushel.
cu. ft.

==

DRILL SIZES FOR

Tap holes
Aluminum and
These

STANDARD THREADS

for die-castings should be .003" to .005" larger than the sizes given, due

zinc alloys.

sizes give

an allowance above the bottom of thread on sizes ^4 to 2 varying

V" Threads, .010" to .055"; for U. S. S. and Whitworth
;

respectively as follows: for

threads, .005" to .027".

These are found by adding

threads, and

to the

of the pitch for U.

S. S.

size at bottom of thread ;4 of the pitch for "V"

No.
and Whitworth, the pitch being equal to 1"

of threads per inch.

In practice

Size

Screw

it

is

better to use a larger drill

if

the exact size called for cannot be had.

WIRE GAUGES
Sizes in decimal parts of an inch

SIZES

OF NUMBERS OF THE UNITED STATES STANDARD GAUGE FOR

SHEET AND PLATE IRON AND STEEL

An Act

Establishing a Standard

Gauge

for Sheet and Plate Iron and Steel

enacted by the Seriate and House of Representatives of the United States of

America in Congress assembled : That for the purpose of securing uniformity the following is established as the only gauge for sheet and plate iron and steel in the United

Be

it

States of

America namely:

LIST OF NINE DIFFERENT

STANDARD GAUGES USED

UNITED STATES
DECIMAL EQUIV.\LENTS

(Inches)

IN

THE

Index
Page

Page

A
11,51,52

Accuracy
Advantages

11

Position

60

Removal

41

Surfaces
Draft
Dull tools

37

Alloys, die cast

21

Table of
Allowances for reaming
For shrinkage

83

Aluminum

22

Ejector pin marks

42

24

Elbows

46

Chemical properties of
Chemical finishes

24

Electro

78

Engraving

Soldering
Pickling
Polishing
Plating

79

Estimates, suggestions on

75

Fillets

Welding

81

Finish

11

32

Finishes, methods of applying

74

12

Fluxes for soldering

79

67

52

alloys

Properties

52

52

of

plating

69
49

75

7i

metals
Assembling, reduction of

Anti-friction

-50,

44

Gating
30,32

Bab])itts

85

Formulas
Baked enamels
Beads
Black finish

85

44
78

38, 64

Gauges

53

Gears
Gold plating
Grinding
Galvanic action

49

74
68
24, 27

8, 2!

Brass die casting

Brass plating

7^

Bushing inserts

56

High pot

81

Impurities in metals
Inserts
Introduction

61

C
Cements
Changes on

39

dies

Cleaning, plating method

Solutions

69

Clearance for tools

Clothias process
Cold enamels
Coloring aluminum

50

70
58
77

40

19,58
72
40

crossing
Interchangeable

Cores,

40
67

Steels

67

Speeds

67

Lead

30

M
Machining advantages
Machining methods
Manufacturing advantages
Metals used
Metal finishes

19

71

Design, range of
Devices using die-castings
Die-casting definition

11

Precision Castings
Pressures

Design

42

Processes

58

causes of inaccuracy

69 to 76

48
59

Co

19,36

Processes of die-casting
Properties of zinc
Punchings, inserts

35

58
27
57

37
34, 35, 36, 37, 38, 40

13

Plunger types

13

67

77

Nickel plating

12

Life of

77

alloys

Deliveries, speed of

Die assembly
Design

Plating instructions
Pipe threads

Die-casting,

54

Lacquers, enamels, etc

13, IS

lubricants

21, 22, 28

78

Combination dies
Compression casting chamber
Copper plating

Cost
Cutting

15. 16, 17, 18

(Juantities

15

Materials

34
38

Shrinkage, no allowance for

Mounting

63

Silver

Operation

63

Sizes in

plating
fractions

38, 51

74
53


Page

Page
Weights and measures
Wire gauges

Soldering die-castings

79

Solders, table of

87

Springs, inserts
Sprue cutters

57

Tap

64

Studs,

56

Taper
Threads

IS

Tilting pot

inserts

Suggestions to purchasers

T
Tables
British thermal unit

84

Co-efficients

88
89

of

friction

Drill sizes for threads

Electro-chemical series
86
84
Gauges for various materials
How to find degrees Fahrenheit or Centigrade
84
Metric conversion tables
86
Nine gauges in general use
92
87
Non-ferrous metal tubing tolerances

Physical properties of metals

Precision alloys

Shrinkage

85

83

90

table

Solders

holes,

sizes

67

52

48
60

Tin plating
Tin alloys

73

Tools, design of

67

Tubing

29

inserts

57

U
Undercuts

44

V
\

acuum processes

N'ariation,

limits

62
52

of

\'ariation in holes, etc

52

W
Walls,

thickness

91

stee!

92
84

Index of

42
46
42

Webs
Weights

of die-castings

87

Standard gauges for iron and

Stubbs steel wire sizes
Useful information

Zinc alloys
Properties
Impurities

25
27

of

28

Illustrations
Page

Page
Precision

Factory,

Fayetteville

Precision Factory, Pontiac

Water pump parts

Speedometer frame
Dispensing machine parts
Sealing machine parts
Steering column parts
Liberty Motor part
Cord tire mold insert
Parts for motors, instruments, etc
Phonograph parts
Electric motor and instrument parts

88
90

4
7
8
9

10
14

Milking machine part

Magneto and generator parts
Soda fountain parts

Elbows
Moving picture machine
Threaded parts

42
43
45

46
plates

47

48

Pipe threads
Gears

48
49

18

Check protector wheel

49

19

Drill stands

20

50
50

16
17

23

Number wheel
Number wheels

Aeroplane speedometer
Speedometer parts
Bouchonj
Babbitt bushings

25

Pulleys

53

26

Magneto housing

54

28

Parts showing various inserts

55

29

Bushing

56

Babbitt bearings

31

Stud inserts

Bearing retainers and shims

Die Shop, Fayetteville
Pulley wheel die
Number wheel die

33

Punched insert
Vending machine
Four parts
Trimming room

Steering column sector die

Die block on miller

37

Die and part for plate

Die worker "checking up"
Handles, knobs

34
35

36
38
39
40
41

51

inserts

56
57

parts

Presses
Carburetor parts
Strut sockets

Vane

for aerial

bomb

Fire Extinguisher parts

59
61
65

66
67

68
76
81

^^^^

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MANCHESTER,
INDIANA 46962

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