These subjects cover the fundamental knowledge that you need in order to master the Die Casting process.
Each subject has a direct application to the Die Casting process and the knowledge gained will be used in subjects in Sections 3 and 4.
Basic Parameters in the Die Casting Process
This subject introduces all the basic parameters, along with their definition, units of measure, and examples of their use in calculations in relation to the Die Casting process.
For anyone that has not studied maths, or basic science for a long time, this is the ideal way to get up to speed. For people that have good maths skills, but are new to Die Casting technology, this subject will provide a quick intoduction to the field.
Fluid Flow in Die Casting
Fluids are fundamental to the Die Casting process, including hydraulic fluid, cooling fluids, die release agents and the molten alloy itself. So a basic knowledge of how they flow, supported with simple calculations is an essential part of a technician's toolkit.
Continuity, flow rate and fluid velocity are explored in detail, followed by the role of pressure, frictional loss and an explanation of what happens at an orifice. This basic knowledge will enable a technician to avoid the sorts of mistakes that are often made in Die Casting by people who have never had the opportunity, or the will, to learn it.
Shot End Characteristics of Die Casting Machines
This subject follows on from the one above and looks at how the Die Casting machine must supply the pressure and the flow rate to fill a cavity with liquid metal.
The student is taught how to collate, calculate and utilise all the relevant information about the shot end parameters of Die Casting machines. Shot force, hydraulic pressures, slow-shot speed, fast shot speed and shot power are all analysed in detail. The origin and use of the PQ-squared diagram is covered, including the effects of shot sleeve diameter, gate area and shot speed setting.
The dynamic pressure pulse, when the plunger comes to a sudden stop, is explained in detail, including how to calculate the amount of flash that will be created.
Heat Flow and Solidification
This module starts with the basic concepts of heat and temperature and the the sources of heat used in the Die Casting industry. The follows the concept of adding heat to liquids and solids and the effect of the heat capacity of different materials.
Basic formulas are explained with worked examples, to give the student the confidence to make simpe calculations involving heat and temperature as it applies in the Die Casting process.
Then follows an explanation of how the solidification process proceeds within the cavity and how this can effect the properties and integrity of the casting.