Initial slide here is black

• Expertise in small-med size, precision castings

• Zinc, Aluminum and Magnesium alloys

• Conventional and Multi-slide tooling

• Design/build proprietary multi-slide casting machines with 450+ in operation today

• Closed-loop communication between production and design ensures advanced technology

Magnesium spikes for Adidas cleats

Hot-chamber, multi-slide

Zinc razor handle for Gillette Mach-3

Hot-chamber, conventional

DYNACAST: WHAT WE DO

Aluminum frame for Apple iPod

Cold-chamber, conventional

FAST FACTS

• Operating profitably for over 70 years

• Over 2 billion die castings shipped annually

• Over 500 new programs launched annually

• 680 machines ranging from 4 to 650 tons

• $471 million in revenue

• 4,100 employees worldwide

• 20 factories in 16 countries

• ISO TS 16949 certified

Telecommunications connector

Seat belt spool

Spikes for football cleats

VALUE-ADDED SERVICES

Cast aluminum component with

runner(Cold chamber, conventional)

Cast component after de-gate

After CNC machining

After Powder coat

After Fly cut

Packaging – foam, bag, sealed plastic bag

Red Bomb Electronic View Finder

After Chromate

Mounted on Red Epic Digital Cinema

Camera

QUALITY

• World-Class DFM (Design For Manufacturing)

• Part consolidation

• Robust manufacturing - improve yields, throughput, die life

• Quality Systems/Continuous Improvement

• TS 16949/ISO 9001

• AQP (Advanced Quality Planning) – cross-functional quality control

• Multiple Quality Inspection Points – Statistical Process Control, adhere to critical dimensions

• Periodic measurements, recordings

• Cost of Quality: Contained

• Eliminates buffer stock, expedited freight costs

• Dock to Stock programs

GLOBAL COVERAGE20 Manufacturing Facilities in 16 Countries

United States

Mexico

Spain

France

Germany

Slovenia

Italy

Singapore

India

China

Korea

Canada United Kingdom

Indonesia

Austria

Malaysia

OUR CUSTOMERSThousands of Customers in Hundreds of Industries

Materials &

Properties

ZincAlloy Description

Zamak 2 The strongest and hardest of the Zamak group. Often specified in applications

requiring optimal wear resistance.

Zamak 3 All-purpose alloy with a unique blend of strength, hardness and ductility.

Zamak 5 Approximately 10% stronger and harder than Zamak 3, with superior impact

strength.

Zamak 7 High purity, ductile alloy with superior formability and finishing characteristics.

ZA-8 The strongest, hardest (hot chamber) zinc-based alloy for the most demanding

applications.

ZA-27 Highest aluminum content, highest strength, highest melting point, and lowest

density of the ZA alloys. High casting temperature requires the cold-chamber

process.

AcuZinc 5 High-copper specialty alloy with superior strength, hardness, wear resistance

properties and enhanced creep strength.

Beric Superior zinc-based alloy in terms of wear resistance, tensile strength, hardness,

and mechanical properties.

EZAC®/

Teck #3

High strength and creep resistant hot chamber zinc-based die casting alloy.

Exceptional tensile strength, comparable to ZA-27.

About Zinc

27th most common element in the Earth’s crust4th most common metal in use today

Zinc is everywhere:• Rock• Soil• Air• Water• Biosphere• Plants• Animals• Human beings

Zinc is essential to life. • Human cells need it to multiply. • Your body needs it to make white blood cells.• Zinc is essential for healthy skin.

Zinc is 100% recyclable and can be recycled forever - zinc die casting alloys can be re-melted and re-used over and over without detriment to their properties.

AluminumAlloy Description

A360.0 Offers higher corrosion resistance, superior strength at elevated temperatures and somewhat

better ductility. Can be more difficult to cast than the other Al alloys.

A380.0 One of the most commonly specified aluminum alloys. Offers the best combination of

casting, mechanical and thermal properties. Fluidity, pressure tightness and resistance to hot

cracking are all very good.

383.0 / ADC12 Often specified when very intricate components require improved die filling characteristics.

Better corrosion resistance than A380.0.

B390.0 Developed for automotive engine blocks. Resistance to wear is excellent, but ductility is low.

Used for die cast valve bodies and sleeve-less piston housings.

413.0 Offers excellent pressure tightness, making it a good choice for hydraulic cylinders and

pressure vessels. Its casting characteristics make it useful for intricate components.

K Alloy Excellent corrosion resistance and thermal conductivity offers unique engineering solutions

and can improve product durability. Improved finishing quality for high polish applications.

44300 Offers excellent castability properties, excellent fluidity and good machinability. Particularly

suitable for difficult thin-wall castings with good elongation properties.

46000 Universal alloy with very good castability for a wide range of applications.

About Aluminum

One of the most sustainable materials in the world.

There is more aluminum in the Earth's crust than any other metal - the 3rd most abundant element in our planet's crust.

• Light• Strong• Corrosion-resistant• Non-magnetic• Non-toxic• Looks good naturally.

Infinitely recyclable – re-use is easy and economical

It takes only 5% of the energy to recycle aluminum compared to making primary aluminum from ore.

Approximately 75% of aluminum produced since 1888 has been recycled and is still in use today.

Magnesium

Alloy Description

AZ91D The most widely specified magnesium die casting alloy. This high-purity alloy has an

excellent combination of mechanical properties, corrosion resistance, and castability.

About Magnesium

8th most abundant element in the Earths crust

Commonly extracted from seawater, where it is the third most common component.

Essential element for all living things. • 4th most abundant mineral in the body.• Produces energy in cells• Helps contract/relax muscles• Synthesizes hormones• Metabolizes calcium

Boasts remarkable strength for its weight, about two-thirds that of aluminum.

Provides design flexibility, enhances structural capabilities and contributes to overall product weight reduction.

Can be recycled back into products displaying the same physical and mechanical characteristics as primary metal.

Alloys in Our Environment

All alloys utilized by Dynacast worldwide are REACH and RoHS compliant:

REACH – Registration, Evaluation, Authorization and restriction of Chemical substances

Aims to improve protection of human health and the environment through better, earlier identification of intrinsic properties of chemical substances.

RoHS – Restriction of Use of Hazardous Substances

Designed to limit or eliminate substances dangerous to the environment and people: mercury, hexavalent chromium, lead, cadmium, polybrominatedbiphenyl (PBB) and polybrominated diphenly (PBDE)

Alloy Properties –Yield Strength

0

100

200

300

400

0

10

20

30

40

50

60

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

EZAC

Teck #3

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy AZ91D C38500 C38000 SAE1008

MPapsi

Brass SteelZn Al Mg

Alloy PropertiesTensile Strength

MPapsi

0

100

200

300

400

0

10

20

30

40

50

60

70

80

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

Beric EZAC

Teck #3

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy 44300 46000 AZ91D C38500 C38000 SAE1008

Brass SteelZn Al Mg

Alloy PropertiesYoung’s Modulus*

* The strain rate behavior of zinc alloys under stress is non-linear and time-temperature dependent, i.e., the ratio of stress to strain is not constant, even at low stresses, and varies with time, resulting in continuous plastic flow under applied load (creep). As a result, zinc alloys do not have a single value for elastic modulus.

GPa

0

10

20

30

40

50

60

70

80

90

100

Zamak 2 Zamak 3 Zamak 5 ZA-8

ZP8

ZA-27

ZP27

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

AZ91D

Zn Al Mg

Alloy PropertiesImpact Strength*

Ft. lb.J

*Results from tests conducted using an ASTM 23 un-notched 0.25" die cast bar

0

10

20

30

40

50

0

10

20

30

40

50

60

70

Zamak 2 Zamak 3 Zamak 5 ZA-8

ZP8

ZA-27

ZP27

ZA-27 AZ91D C38500 C38000

BrassZn Mg

-0,5

0,5

1,5

2,5

3,5

0

1

2

3

4

AcuZinc 5 EZAC

Teck #3

A380.0

LM24

46500

383.0

47100

ADC12

LM26

Alloy PropertiesImpact Strength*

Ft. lb.

*Results from tests conducted using notched Charpy samples

J

Zn Al

0

20

40

60

80

100

120

140

0

10

20

30

40

50

60

70

80

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

Beric A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy 44300 46000 AZ91D

Alloy PropertiesThermal Conductivity

W/m KBtu-ft / h-ft

Zn Al Mg

Alloy PropertiesElongation

% in 50mm

0

5

10

15

20

25

30

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

Beric EZAC

Teck #3

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy AZ91D C38500 C38000 SAE1008

Brass SteelZn Al Mg

Alloy PropertiesElectrical Conductivity

% IACS

0

5

10

15

20

25

30

35

40

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy 44300 46000 AZ91D

Zn Al Mg

Alloy PropertiesShear Strength

MPapsi

0

50

100

150

200

250

300

350

0

5

10

15

20

25

30

35

40

45

50

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

A360.0 A380.0

LM24

46500

413

47100

AlSi12CU

LM6

AZ91D

Zn Al Mg

Alloy PropertiesHardness

% IACS

0

20

40

60

80

100

120

140

Zamak

2

Zamak

3

Zamak

5

Zamak

7

ZA-8

ZP8

ZA-27

ZP27

AcuZinc

5

Beric EZAC

Teck #3

A360.0 A380.0

LM24

46500

383.0

ADC12

LM26

B390 413

47100

AlSi12CU

LM6

K Alloy 44300 46000 AZ91D C38500 C38000 SAE1008

Brass SteelZn Al Mg

VISIT OUR MATERIAL SELECTOR APPLICATION

WWW.DYNACAST.COM

Material ComparisonsAvailable on Our Website

Material SelectorAvailable on Our Website

INTRODUCTION TO DIE CASTING

Ignition housing/ steering wheel lock

The Die Casting ProcessCold Chamber

The Die Casting Process

Hot Chamber Conventional

Die Casting ProcessesProcess Maximum Part Weight

Cold Chamber Aluminum

135 Ton .68 kg 1.5 lb

250 Ton 1.8 kg 4 lb

350 Ton 2 kg 4.5 lb

400 Ton 2.7 kg 6 lb

500 Ton 3.6 kg 8 lb

Conventional Zinc

200 Ton 5 lb

A2 – Zinc 50 g .11 lb

A2 SIS – Zinc 60 g .13 lb

A3 SIS – Zinc,

Magnesium

160 g .35 lb

Die Casting Advantages

• Thin wall sections – 0.5mm or thinner• Thermal & electrical conductivity• Excellent EMI/RFI shielding properties• Very good noise damping qualities• Excellent impact strength• Easily plated or finished• Complex shapes with close tolerances• High production rates• High corrosion resistance• Reduces assembly costs• Use of metal creates perceived added

value to final product

Advantages vs. Other processes

Other Processes Die Casting

Plastics Die castings are stronger, offer faster cycles, provide better heat resistance

and shielding properties.

Sand Casting Die castings provide for closer tolerances, better surface finishing and less

labor cost per casting.

Forgings Die castings can produce more complex shapes, thinner sections and holes

can be cored.

Stampings Die castings have better part-to-part uniformity, less scrap and closer

tolerances

Screw Machining Die castings have fewer operations, less scrap, faster cycles and offer better

part-to-part uniformity.

Die Casting Design TipsDraft

• Slight taper on internal walls• Offsets effects of shrinkage• Ejector pins easily push out the casting (from cavity) Draft

Die Casting Design Tips

Fillets and Radii• Sharp corners should be avoided• Design inside corners with fillets• Design outside corners with radii• Strengthens castings• Improves metal flow through reduced turbulence

RadiusFillet

Die Casting Design Tips

Weight Reduction• Reduces cross-sectional area by designing pockets in solid sections• Decreases cycle time• Reduces cost

D i e C a s t i n g D e s i g n

TipsRibs

• Use ribs to increase strength of the component• Blend ribs with fillets and radii to eliminate sharp corners

Die Casting Design TipsThreads

• Design flats on the root diameter at the parting line• Full threads are possible

Parting Line

Die Casting Design Tips

Design to Assist Flow• Smooth corners and uniform sections allow fast filling without producing metal

flow turbulence• Triangle flat added for better flow across part and cone feature helps fill post

Allows better flow across part

Cone feature helps fill post

Difficult to fill

Die Casting Design Tips

Design to Assist Flow• Long “windows” or “slots” severely restrict metal flow• Round holes assist metal flow

Case Studies

There are six basic ways to reduce component cost:• Lower raw material cost

• Reduce scrap

• Increase the speed and efficiency of the production process

• Eliminate secondary operations

• Add integral features to the component

• Combine multiple components into a single-piece design

Summary

• Take full advantage of all the die casting process can offer

• Avoid over-engineering a component

• Keep an open mind about what manufacturing process will work in your application

• Our engineering staff is always ready to evaluate your component design and possible conversion candidates

• Add integral features to the component

• Early supplier involvement = the most cost effective component design

Laser mount for

Blu Ray DVD

player

THANK YOU