ADCA 2014 Diary

D I A R Y 2 0 1 4

ADCA Cover 2014.indd 1 16/07/13 8:22 AM

Houghton Australia Pty Ltd www.houghton.com.auTel: 1300 736 642

Hi-Temp® - Heat transfer fluids

Cerfa Kleen® - Cleaning chemicals

Aqua Quench® - Casting quench solutions

Houghto Safe® - Fire resistant hydraulic fluids

Fluidcare® - Chemical management services

Rust Veto® - Corrosion inhibiting fluids

Hocut® - Metal cutting fluids


Do you want to produce the highest

quality products?

Then you need to use the steel produced by the World’s Leading Tool Steel producers Bohler-Uddeholm. Each year our steel Mills in Austria, Sweden, Germany and

Brazil spend millions of dollars on researching developing grades for the Diecasting industry.

For fast friendly efficient service contact your right partner

Bohler Uddeholm

www.buau.com.au

DIEVAR

ADCA Pages 2014.indd 1 16/07/13 8:21 AM

Just add FosecoWe’re dedicated to realising the power of partnership. Simply by working closely with you, we can understand your needs today, instantly creating new value, whilst driving development forward for tomorrow.

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Houghton Australia Pty Ltd www.houghton.com.auTel: 1300 736 642

Hi-Temp® - Heat transfer fluids

Cerfa Kleen® - Cleaning chemicals

Aqua Quench® - Casting quench solutions

Houghto Safe® - Fire resistant hydraulic fluids

Fluidcare® - Chemical management services

Rust Veto® - Corrosion inhibiting fluids

Hocut® - Metal cutting fluids



www.pyrotek.info/foundry email: [email protected]

Phone: 1300 136 662


The Australian Die Casting Association (also known as ADCA) represents the Die Casting industry in Australia.

The objecTives of The AssociATion Are To promoTe: • the advancement of the Australian die casting industry • the education and development of people in the industry • co-operation between the Association, the industry and Government

These objecTives Are meT Through: • regular branch meetings and plant visits • seminars, workshops and conferences • publishing of the Die Casting Bulletin magazine • development and delivery of education programs • support for research and development programs

AbouT ADcA

Australian Die Casting Association ABN: 68 958 369 640

National Secretary – Jennifer Luxford PO. Box 2194, Bayswater, Victoria, 3153, Australia Email: [email protected] Web. www.diecasting.asn.au

conTAcT DeTAiLs


AAC Alloy Designation

Use3 Silicon (Si) Iron4 (Fe) Copper (Cu) Manganese (Mn)

Magnesium5 (Mg)

Chromium (Cr)

Nickel (Ni) Zinc (Zn) Tin (Sn) Lead (Pb) Titanium (Ti) Other Each

Elements Total

Aluminium (Minimum)

AA303 sp 4.0-5.0 0.86 2.0-4.0 0.76 0.15 0.10 0.30 0.50 0.15 0.15 0.20 0.05 0.20 rem

AA305 p 8.5-10.5 0.90 2.0-4.0 0.50 0.6-1.5 0.10 0.50 1.00 0.15 0.25 0.25 0.05 0.20 rem

AA307 D 9.0-11.5 1.00 0.7-2.5 0.50 0.30 0.10 0.50 2.00 0.25 0.35 0.20 0.05 0.20 rem

AA309 sp 4.5-5.5 0.25 1.0-1.5 0.05 0.50-0.6 0.05 0.20 0.05 0.15 rem

AA311 sp 4.0-6.0 0.15 1.0-1.5 0.05 0.05 0.10 0.20 0.05 0.20 rem

cA313 D 7.5-9.5 1.30 3.0-4.0 0.50 0.30 0.10 0.50 3.00 0.25 0.35 0.20 0.05 0.20 rem

AA315 D 10.5-12.0 1.30 3.0-4.5 0.50 0.10 0.10 0.50 1.00 0.35 0.25 0.20 0.05 0.20 rem

AA317 sp 6.0-8.0 0.80 1.5-2.5 0.20-0.60 0.35 0.10 0.35 1.00 0.15 0.25 0.20 0.05 0.20 rem

AA319 p 11.0-13.0 0.70 0.8-1.3 0.35 0.8-1.3 0.10 1.0-2.5 0.25 0.20 0.15 0.20 0.05 0.20 rem

bA323 sp 7.5-8.5 0.30 3.5-4.0 0.30-0.50 0.30-0.40 0.05 0.10 0.15 0.05 0.15 rem

bb325 sp 7.5-8.5 0.80 2.0-3.5 0.10-0.30 0.20-0.50 0.30 0.20-0.50 0.10 0.20 0.15 0.05 0.15 rem

cA327 sp 5.5-6.8 0.25 3.0-4.0 0.50 0.10-0.18 0.10 0.10 0.15 0.05 0.15 rem

Ac3318 D 13.8-14.5 0.6-1.0 1.9-2.2 0.35-0.50 0.50-0.7 1.0-1.4 0.10 0.05 0.15 rem

AA335 D 9.6-12.0 0.904 1.5-3.5 0.50 0.30 0.10 0.50 1.00 0.30 0.25 0.20 0.05 0.20 rem

AA337 p 8.5-10.5 0.804 2.0-4.0 0.50 0.6-1.57 0.10 0.50-1.5 0.50 0.20 0.15 0.20 0.05 0.20 rem

AA339 sp 5.0-7.0 0.804 2.0-4.0 0.50 0.50 0.10 0.30 1.00 0.20 0.15 0.20 0.05 0.20 rem

cA401 sp 12.0-13.0 0.40 0.10 0.10 0.05 0.05 0.10 0.20 0.05 0.15 rem

cb401 sp 12.0-13.0 0.40 0.10 0.05 0.05 0.05 0.10 0.20 0.05 0.20 rem

cc401 sp 12.0-13.0 0.40 0.10 0.05 0.05 0.05 0.10 0.20 0.05 0.20 rem

DA401 sp 10.0-13.0 1.00 0.60 0.50 0.25 0.10 0.50 0.40 0.15 0.15 0.20 0.05 0.25 rem

eA401 sp 11.0-13.0 0.60 0.15 0.50 0.10 0.10 0.10 0.15 0.05 0.15 0.20 0.05 0.20 rem

Ab405 sp 6.5-7.5 0.15 0.10 0.10 0.05 0.10 0.20 0.05 0.15 rem

AA5059 s 0.30 0.60 0.10 0.3-0.7 3.0-6.0 0.10 0.10 0.05 0.05 0.20 0.05 0.15 rem

Ac603 sp 6.5-7.5 0.15 0.05 0.03 0.45-0.7 0.05 0.20 0.05 0.15 rem

cA605 D 9.0-10.0 0.7-1.1 0.60 0.35 0.45-0.6 0.50 0.50 0.15 0.05 0.25 rem

bA701 s 0.25 0.50 0.15 0.15 0.50-0.7 0.40-0.6 0.10 4.8-5.7 0.05 0.05 0.15-0.25 0.05 0.15 rem

AA94110 2.6-3.3 0.40 0.03 0.03 (also 0.01 sb and 0.01 cd) 0.01 0.03 0.15 rem

chemicAL composiTion LimiTs of ALuminium ingoTs AnD cAsTings


fooTnoTes for chemicAL composiTion LimiTs of ALuminium ingoTs AnD cAsTings

1. Composition in percent maximum unless shown as a range or a minimum.

2. Analysis is made only for the elements for which specific limits are shown except for minimum purities of 99.0 percent or greater. If however the presence of other elements is suspected to be, or in the course of routine analysis is indicated to be, in excess of the specified limits, a further analysis is made to determine that these other elements are not in excess of the amount specified.

The aluminium content of unalloyed aluminium is the difference between 100.00 percent and the sum of all other metallic elements present in amounts of 0.010 percent or more, each expressed to the second decimal place before determining the sum.

3. Use: S = SAND CASTING • P = PERMANENT MOULD CASTING • D = PRESSURE DIE CASTING

Reproduced with permission from the Australian Aluminium Council Ltd

4. For these alloys only, iron maximum relates to ingot. The maximum iron for castings may vary as follows:

• If Fe maximum in ingot is 0.9% then castings 0.40% greater.• If Fe maximum in ingot is 0.8% then castings 0.20% greater.• If Fe maximum in ingot is 0.7% then castings 0.10% greater.• If Fe maximum in ingot is 0.20% (or less) then castings 0.05% greater.

5. For these alloys only, magnesium maximum relates to ingot. The maximum magnesium for castings may vary as follows: If Mg maximum in ingot is 0.15% (or less) then castings 0.05% less.

6. Iron + manganese not to exceed 1.3%.

7. For castings in this alloy the magnesium range is 0.50-1.5.

8. This is where alloy designation specifies sodium or strontium addition, sufficient amounts are added to provide sufficient eutectic modification, so the alloy can be AC331.

9. Beryllium is added to control oxidation 0.002- 0.005 %

10. Alloy AA941 is not a casting alloy, it is used as an aluminium hardener.

Reproduced with permission from the Australian Aluminium Council Ltd.


neAresT reLATeD composiTion specificATions

AAC Alloy British Standard Alloy

Aluminium Association (US) Alloy Type

German Alloy Japanese (JIS) Alloy

ISO Alloy

bA303 Lm4 319 Aisi5cu3 Ac2A Aisi5cu3

AA305 Lm26 332 Aisi10cu Ac8b -

AA307 Lm2 - Aisi10cu ADc12 -

AA309 Lm16 355 Aisi5cu1mg Ac4D Aisi5cu1mg

AA311 - A305 Aisi5cu1 - -

cA313 Lm24 A380 - - Aisi8cu3fe

AA315 - A384 - - -

AA317 Lm27 328 Aisi7cu2mn - -

AA319 Lm13 A336 Aisi12mg1cu1 Ac8A -

bA323 - - - -

bb325 Lm24 - Aisi8cu3fe - Aisi8cu3fe

cA327 Lm21 319 Aisi6cu4 Ac2b -

Ac331 - - -

AA335 - 383 - ADc12 -

AA337 Lm13 332 Aisi10cu Ac8b -

AA339 Lm4 319 Aisi5cu3 Ac2b Aisi6cu4

cA401 Lm6 A413 Aisi12 Ac3A Aisi12

cb401 Lm6 A413 Aisi12 Ac3A -

cc401 Lm6 A413 Aisi12 Ac3A -

DA401 Lm20 A413 Aisi12fe ADc1 Aisi12cufe

eA401 Lm6 413 - ADc1 Aisi12fe

Ab405 - A444 - - -

AA505

AA601 Lm25 A356 Aisi7mg Ac4c Aisi7mg

Ac601 Lm25 A356 Aisi7mg Ac4c -

cc601 Lm25 A356 Aisi7mg Ac4c -

DA601 Lm25 356 Aisi7mg Ac4c -

AA603 Lm25 A357 Aisimg0.5 - -

Ac603 Lm25 A357 Aisimg0.5 - -

cA605 - 360 Aisi10mgfe - -

bA701 DTD5008 712 AiZn5mg - AiZn5mg

1. This table is to be referred to as a guide only. Reproduced with permission from the Australian Aluminium Council Ltd.


chemicAL composiTion LimiTs of Zinc Die cAsTing ALLoYs

Zinc (Zn) (Minimum)

Nickel (Ni)

Silicon (Si)

Tin (Sn)

Cadmium (Cd)

Iron (Fe)

Lead (Pb)

Titanium (Ti)

Chromium (Cr)

Magnesium (Mg)

Copper (Cu)

Aluminium (Al)

Uses

Alloy Designation

rem

0.001

0.02

0.001

0.003

0.020

0.003

-

-

0.035-0.06

2.7-3.3

3.8-4.2

hc

ZnAl4cu3

rem

0.001

0.02

0.001

0.003

0.020

0.003

0.035-0.06

0.03

3.8-4.2

hc

ZnAi4

rem

0.001

0.02

0.001

0.003

0.020

0.003

0.035-0.06

0.7-1.1

3.8-4.2

hc

ZnAi4cu1

rem

0.001

0.035

0.002

0.005

0.035

0.005

0.02-0.03

0.9-1.3

8.2-8.8

hc

ZnAi8cu1

rem

0.001

0.020

0.001

0.003

0.020

0.003

0.005

3.2-3.8

6.6-7.2

hc

ZnAi7cu3

rem

-

0.05

0.002

0.005

0.05

0.005

-

-

0.02-0.03

0.5-1.2

10.5-11.5

cc

ZnAi11cu1

rem

-

0.04

0.003

0.004

0.04

0.005

0.15-0.25

0.1-0.2

0.02

1.0-1.5

0.01-0.04

cc

Zncu1crTi

rem

0.07

0.002

0.005

0.07

0.005

-

-

0.012-0.02

2.0-2.5

25.5-28

cc

ZnAi27cu2

chemicAL composiTion (en1774) guArAnTeeD, AnALYsis (in%)

Reproduced with the permission of Nyrstar


This guide is to help designers and material specifiers to better understand the capabilities of zinc casting alloys for product applications.

ADvAnTAgesZinc casting alloys are versatile engineering materials. No other alloy system provides the combination of strength, toughness, rigidity, bearing performance and economical castability. Listed are zinc alloy attributes which can reduce component costs. Improving precision, quality and product performance are other zinc alloy design advantages discussed in this brochure.

process fLexibiLiTYVirtually any casting process can be used with zinc alloys to satisfy virtually any quantity and quality requirement. Precision, high volume die casting is the most popular casting process. Zinc alloys can also be economically gravity cast for lower volumes using sand, permanent mold, graphite mold and plaster casting technology.

precision ToLerAncesZinc alloys are castable to closer tolerances than other metals or molded plastics, therefore presenting the opportunity to reduce or eliminate machining. “Net Shape” or “Zero Machining” manufacturing is a major advantage of zinc casting.

sTrengTh AnD DucTiLiTYZinc alloys offer high strengths (to 60,000 psi) and superior elongation for strong designs and formability for bending, crimping and riveting operations.

ToughnessFew materials provide the strength and toughness of zinc alloys. Impact resistance is significantly higher than cast aluminium alloys, plastics, and grey cast iron.

rigiDiTYZinc alloys have the rigidity of metals with modulus of elasticity characteristics equivalent to other die castable metals. Stiffness properties are therefore far superior to engineering plastics.

AnTi spArkingZinc alloys are non sparking and suitable for hazardous location applications such as coal mines, tankers and refineries.

Zinc cAsTing ALLoYs


Zinc cAsTing ALLoYsbeAring properTiesBushing and wear inserts in component designs can often be eliminated because of zincs excellent bearing properties. For example, zinc alloys have outperformed bronze in heavy duty industrial applications.

eAsY finishingZinc castings are readily polished, plated, painted, chromated or anodized for decorative and/or functional service.

Thin WALL cAsTAbiLiTYHigh casting fluidity regardless of casting process, allows for thinner wall sections to be cast in zinc compared to other metal.

mAchinAbiLiTYFast trouble free machining characteristics of zinc materials minimize tool wear and machining costs.

LoW energY cosTsBecause of their low melting temperature, zinc alloys require less energy to melt and cast versus other engineering alloys.

Long TooL LifeLow casting temperatures result in less thermal shock and therefore extended life for die casting tools. For example, tooling life can be more than ten times that of aluminium dies

cLeAn AnD recYcLAbLeZinc alloys are among the cleanest melting materials available. Zinc metal is non-toxic, and scrap items are a reusable resource which are efficiently recycled.


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DISCLAIMER: This publication is provided on the basis that Link Media is not responsible for the results of any actions taken on the basis of information in these publications, nor for any error in or omission from these publications and that the firm is not hereby engaged in rendering advice or services. Link Media expressly disclaim all and any liability and responsibility to any person in respect of anything and of the consequences of anything done, or omitted to be done by any such a person in reliance, whether wholly or partially upon the whole or any part of the contents of this publication. Contents Copyright 2013 by Link Media. All rights reserved. No article or advertisement may be reproduced without written permission. Link Media, PO Box 1879, Christchurch 8140, NZ.

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Just add FosecoWe’re dedicated to realising the power of partnership. Simply by working closely with you, we can understand your needs today, instantly creating new value, whilst driving development forward for tomorrow.

This collaborative philosophy permeates everything we do, building strong and productive long-term relationships. And, as a result, the solutions we provide bring fresh ideas to life, maintaining the most comprehensive portfolio available.

So, release your true potential: just add Foseco.

+ Partnership

+ Global Technology - Locally Delivered

+ Creative, Innovative Solutions

+ Expert Advice

+ Reliability

+ Knowledge Leadership

Phone +(61) 2 9914 5500

Fax +(61) 2 9914 5547

www.foseco.com.au


Do you want to produce the highest

quality products?

Then you need to use the steel produced by the World’s Leading Tool Steel producers Bohler-Uddeholm. Each year our steel Mills in Austria, Sweden, Germany and

Brazil spend millions of dollars on researching developing grades for the Diecasting industry.

For fast friendly efficient service contact your right partner

Bohler Uddeholm

www.buau.com.au

DIEVAR


Documents

ADCA 2014 Diary