Attending NADCA Die Casting Congress & Exposition? Select the Right Casting Process 26 Sep 2024, 6:14 pm

Selecting the Right Casting Process: ZA12 alloy using Graphite Permanent Molding, the Most Cost-Effective process for Annual Quantities Up to 20,000 Pieces

If you are attending the NADCA Die Casting Congress & Exposition 2024, you may be surprised by the significant investment required for the latest die-casting options, especially if you are producing less than 20,000 parts annually.

When deciding on the most cost-effective casting process for producing zinc alloy components, especially when manufacturing 150 or up to 20,000 pieces annually, it’s essential to evaluate various factors to determine the optimal method. Here’s a guide to help you make an informed decision:

1. Part Complexity

For intricate and detailed shapes, die-cast and investment castings are typically preferred due to their ability to handle fine details and complex geometries. However, if the parts are relatively simple, permanent molding is a viable alternative, offering a balance between complexity and cost. Graphite molds can be cut to exacting tolerances in combination with the highly fluid ZA alloys allowing raised graphics and artwork to be cast in fine detail.

2. Production Volume

With an annual production volume of 150 up to 20,000 pieces, permanent molding is a suitable choice. It strikes a balance between high-speed processes like die casting, which is more cost-effective for very high volumes. Permanent molds can be used for years, making them economical for low to medium-sized production runs.

3. Material Selection

Zinc-aluminum alloy components benefit from the precision and durability of permanent molding. The process involves using a graphite mold to create parts with consistent properties and surface finish. This method is ideal for ZA12, as it supports the material’s casting properties while providing reliable net shape results. ZA alloys offer yield strengths from 29,000 to 54,000 psi and tensile strengths from 37,000 to 64,000.They have replaced aluminum, brass, and cast iron castings. Complete alloy information is available here.

4. Surface Finish

Graphite permanent molding offers as good of surface finish as diecasting. For most applications, the surface quality achieved with permanent molding is sufficient and cost-effective. If an exceptional finish is critical, you may consider additional finishing processes.

5. Dimensional Accuracy

Permanent molding provides good dimensional accuracy and can handle tolerances that are generally acceptable for many applications. Tolerances can be held +/-.005” for the first inch of dimension in any direction with an added +/-.002”/inch for each additional inch. 2 degrees of draft is required for inside and outside surfaces perpendicular to the parting line. Small holes can be cored. If your project demands very tight tolerances, secondary machining can be done in house for an additional cost.

6. Time and Speed

Graphite permanent molding is a relatively fast casting process compared to some other methods. Tools can be cut in a week providing the 3D models are available. It allows for quicker production runs and faster turnaround times while still being economical. This speed is advantageous for initiating the launch of a new product, maintaining production schedules and meeting deadlines. We call it rapid production.

7. Cost

Permanent molding is often more cost-effective than die-casting for medium production volumes. Die casting might offer lower costs for very high volumes due to its speed and use of die casting machines. However, permanent molding provides a more economical solution than sand casting or investment casting for quantities as low as 150 and up to 20,000 pieces. In order for the total cost of acquisition to be evaluated, one must include the initial investment in molds and the per-unit cost of production over the product life cycle. Graphite permanent mold has a low cost of entry with a reasonable cost per part.

8. Geometric Features

Zinc aluminum components often involve specific geometric features. Permanent molding supports a wide range of geometries, but it’s essential to ensure that the mold design can accommodate the part’s features. The process is well-suited for parts with moderate complexity and varying section thicknesses up to .375” thick.

9. Achievable Quality

Permanent molding offers a reliable level of quality, including good surface finish and dimensional stability. It is an excellent choice when you need a consistent and high-quality outcome without the high costs associated with other methods. While investment casting might provide a finer finish, permanent molding is generally sufficient for most applications within the specified production range.

Conclusion

For annual quantities of up to 20,000 graphite components, graphite permanent molding stands the test of time as a highly cost-effective and practical casting process. It balances cost, quality, and production efficiency, making it a suitable choice for producing high-quality zinc-aluminum alloy parts with moderate complexity and good dimensional accuracy. By choosing permanent molding, you can achieve reliable results while keeping production costs in check. To see more of our foundry’s casting capabilities and work visit https://albco.com/our-work/.

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How to Handle Casting Design Projects Like a Pro 1 Jun 2018, 2:51 pm

A first impression is everything. And as long as you have a grasp on things, you’re going to do just fine. Now, grab the handle and let’s go! Wait, did you think we were giving life advice here? It’s a great motto to live by, but we’re actually referring to physical handles.

The key to creating a great first impression with a handle is to mix quality, style, performance and attention to detail in equal measure. For a foundry, this means having the casting capabilities to mold a customized manufactured part with distinctive features.

Handles have the power to add a certain wow factor to almost any object and users will know the quality of the material from the moment it’s touched. But most importantly, a handle should stand the test of time and enable a user to maximum the tool, machine or equipment they’re operating with complete strength and comfort.

Zinc-aluminum (ZA-12) casting alloys are key to molding a superior handle. ZA-12 has become the preferred alloy over such materials as aluminum, brass and cast iron. Why? When you couple ZA-12 with graphite permanent molding, you make for precision cast tolerances, short lead times, excellent detail and superior finish.

The process begins with the pouring of molten metal into graphite permanent mold. The parts are ejected from the semi-automatic machines for manual trimming. Then, samples are inspected for validation before rapid production. This means you can get the handle you need in a timely manner at a fraction of the cost of other manufacturing processes. For example, Albco Foundry & Machine can tool up a permanent mold at a cost between $1,500 and $4,500. In addition, Albco Foundry provides casting in steel shafts and custom powder coating supplied to the specifics of your handle request.

Whether you need a handle for lawn and garden equipment, gun safes, automated teller machines (ATMs), commercial refrigerators or hospital beds, Albco Foundry’s flexible process can handle your design and create a customized solution. Call or email us today to learn more!

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ALBCO Casts Resurgence with ISO Certification and New Website 8 May 2018, 6:14 pm

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Molding the Future at ALBCO 19 Apr 2018, 1:47 pm

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Eggcellent Idea! Graphite Permanent Mold Helps Incubator Care for Eggs 23 Mar 2018, 4:03 pm

Which came first, the chicken or the egg? It’s a valid question people have been asking for thousands of years. Think about it for a moment. Chickens hatch from eggs, which are laid by chickens. See the dilemma?

Okay, while we may never know the true origins, we do understand hatching chicken eggs aren’t just done in a coop on the farm. Today’s hatcheries feature large-scale egg incubators with enough computers and machine technology to power NASA. We’re not talking about a few eggs here. In a given year, an incubator can mass produce 15 million chicks.

The process starts with each egg cleaned and inspected before being placed into an incubator. These devices range from the size of your kitchen refrigerator to a complete storage unit. Incubators control the temperature and humidity and turn the eggs until just before the moment they hatch.

That’s when Chick Master chirps in. Serving hatcheries and farms across the globe, the company based in Medina, Ohio specializes in incubation, environment and hatchery management products designed to achieve the most hatchability and chick quality in the most efficient, cost effective way.

“What does a poultry hatchery have to do with ZA-12?” Good question; it’ll all make sense shortly. Chick Master purchased a gear box to be utilized within one of its commercial incubators, which can hold up to 21,000 eggs. The gear box is a critical component of the hatching process and simulates a chicken hen by gently turning eggs in a controlled environment.

Unfortunately, the design wasn’t meant for hatching. Rather, it was intended to move something else.

Remember the classic 76 moving gas station signs? They had the perfect rotation (not too fast and not too slow) that could be seen for miles. Well, this particular gear box was intended to do just that with a high torque and low RPM motor. Plus, it did not have the gusset support or bolt pattern. Great for a gas station sign! Not so much for a hatchery incubator.

The team at Chick Master researched alternative options and discovered the gear box could be retrofitted with parts produced by Albco Foundry and Machine. Not just any parts. These components are made of ZA-12 that offer unparalleled strength, superior bearing properties and versatile architecture. That’s what makes the alloy an exceptional choice over the material competition featuring aluminum, brass and casting iron castings.

Chick Master ordered lots of 50 pieces that were machined complete along with O-rings and bronze bushings pressed into place at a rate of $35 per piece. Tooling costs came in at $4,500, which provided the company with a viable solution.

The graphite permanent mold process provides a quality surface and is very close to the final shape of the part, reducing the need for surface finishing. However, ZA’s near net shape processing options allow for cast-to-size shapes, greatly scaling back or eliminating secondary machining and processing costs. In addition, ZA’s fast, easy machining can often compensate for material cost differences.

As a result, Chick Master’s production quantities are commonly low with most machines modified based on the customer’s request.

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Turning Designs into Reality: The Graphite Permanent Mold (GPM) Casting Process 16 Oct 2017, 9:06 pm

ZA alloys feature a unique material combination that’s versatile for a variety of casting processes. For example, cast iron and bronzes are normally sand cast, which require extensive machining to obtain final tolerances. However, the process of graphite permanent molding coupled with ZA makes for short lead times, precision cast tolerances, excellent detail and superior surface finish.

The process begins with the pouring of molten metal into molds machined from solid graphite. The parts are ejected from the semi-automatic machines for manual trimming.

This type of casting combines modest tooling costs with good precision and surface detail, serving as a low-cost alternative to die casting. Speed plays a major factor as graphite can be machined, allowing for rapid engineering changes, often in hours or days as opposed to weeks or a month for other foundry processes. Additional elements include improved tolerances, finish and elimination of secondary machining. These allow the GPM process to exceed the potential of sand and permanent mold casting.

Graphite permanent mold is ideal for prototyping, especially when higher pre-production quantities are needed. Albco’s in-house mold shop is capable of producing prototypes and molds in less than a few days.

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The ZA-12 Advantage 12 Sep 2017, 6:19 pm

ZA casting alloys feature the best in zinc-aluminum engineering materials. ZA-12 specifically has emerged as the alloy of choice over aluminum, brass and cast iron castings. But, why is that the case? For starters, the process of graphite permanent molding coupled with the versatile family of ZA makes for short lead times, precision cast tolerances, excellent detail and superior finish.

Built for Toughness

ZA alloys preserve high tensile strength and endurance, performing at its best under the most stressful conditions. Strengths can range upwards of 64,000 psi depending on the alloy and process selection.

Cut Above the Rest

ZA alloys machine rapidly, with very little impact on tool wear. Machining rates are often equivalent to free machining brass and can be three times faster than for the cast iron.

Corrosion Resistance

ZA materials possess good corrosion resistance under atmospheric conditions and in various aqueous solutions and industrial and petroleum products. Surface treatments such as chromating, plating, painting and zinc anodizing provide additional corrosion protection.

A Glowing Finish

ZA materials can be polished to a bright lustrous chrome-like finish, which can be lacquered for longevity. Plating, chromating and painting are other conventional finishes that can be applied.

Now that we know the design features of ZA-12, let’s take a look at how and why the alloy has replaced other metal materials.

ZA-12 vs. Bronze

ZA alloys have inherent bearing properties and are being used as direct substitutes for larger bronze industrial bushings and bearings. ZA alloys are substantially lower in cost than bronze and up to 43% lighter.

ZA-12 vs. Cast Iron

ZA-12 weighs the same as cast iron and both roughly have the same strength. However, ZA-12 machines three times easier than cast iron allowing for faster cycle times and reduced tool wear.

ZA-12 vs. Aluminum

ZA-12, as cast, is harder, stronger and heavier than sand and die cast aluminums.

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