Engineering Bulletins
for OEM Product Designers, Engineers, Buyers & Purchasing Specifiers,
and Independent Product Design Consultants
These Die Casting Engineering Bulletins & White Papers are industry association, supplier and CWM publications under seven headings to aid OEMs in optimizing their component design, specifications and production processing. Each document, in PDF format, is available from CWM to Design Center registered OEMs and OEM Product Design Consultants by immediate download. Adobe Acrobat Reader required for viewing.
More extensive design guides and manuals, found in other Resource Center sections, are also cross-referenced here.
Engineering Bulletins Section Contents
1
OVERALL PART DESIGN PREPLANNING GUIDANCE
2
PART DESIGN CONSIDERATIONS FOR DIE CASTINGS
3
EVALUATING MATERIALS/ALLOYS
4
DESIGN SPECIFICATIONS FOR DIE CASTINGS
5
PROTOTYPING FOR DIE CASTING
6
DIE CASTING TOOLING CONSIDERATIONS
7
DIE CAST PRODUCTION & SURFACE FINISHING
1
OVERALL PART DESIGN PREPLANNING GUIDANCE
Die Casting Design & Production Preplanning Guide
(No. 5114) Preplanning Guide to aid OEMs considering custom die cast part production and reviewing existing literature. Organizes selected industry and CWM design resources into a 7-step sequence for the planning process. The source of each die casting design and production bulletin, tech brief, guide, checklist and reference manual is listed, with many available for Web downloading or forwarding by Email. Bulletin contains direct Web links to aid access or requests for all listed documents. PDF, 1 page. Download Bulletin No 5114.
NADCA Collaborative Engineering White Paper
(No. 5115) This in-depth White Paper from the North American Die Casting Assn. details how collaborative engineering between OEM engineers and custom die caster engineering can result in improved production efficiencies and reduced part costs. The case study method is used to discuss cost-saving opportunities for existing parts at the point of tooling replacement or required product design revisions, as well as for clean
sheet designs. PDF, 6 pages. Download Bulletin No 5115.
Evaluating Materials & Processes
(No. 020) Introductory overview and guide to optimum materials and alternate process selection. Contains a physical and mechanical materials properties comparison chart for the most widely used Al, Mg & Zn die casting alloys. PDF, 4 pages. Download Bulletin No 020.
Designers & engineers may also wish to reference the following, listed elsewhere in the Center:
The Plastic vs Die Casting Process Decision
(No. 37) If a structural component requires stiffness and extra strength, a proposed plastic part is usually a good candidate for production as a light weight magnesium die casting. If EMI shielding and green recyclability are a concern, die cast Mg can be a hands down choice: Application/Tech Briefs
12 Ways to Reduce the Costs of Die Cast Parts
(No. 4310) 6-page Guide outlines 12 key cost drivers that design engineers can leverage during the product design stage to yield significant cost savings in the custom production of die cast components. Described more fully and can be downloaded by registered OEMs & consultants from the Resource Center section: Design Guides.
2
PART DESIGN CONSIDERATIONS FOR DIE CASTINGS
Designing Optimum Part Shapes
(No. 021) Introductory guide to developing the optimum component configuration for cost-effective die cast processing. Provides overview of design features which enable the designer to capitalize on the inherent advantages of net-shape die cast production. PDF, 4 pages. Download Bulletin No 021.
NADCA: Pointers for Designing Die Castings
(No. 5116) Die castings offer exceptional design freedom while at the same time achieving excellent mechanical properties for a product component. Selected features should be designed to enhance casting quality and avoid unnecessary casting costs. This article offers details on key points to consider in optimizing the cost-performance equation for a die cast part. PDF, 3 pages. Download Bulletin No 5116.
Designing for Servicing & Recyclability
(No. 024) Facts on the material recycling infrastructure long in place for die cast metal parts and recyclability questions designers should ask in selecting materials and manufacturing processes for "green" component design. PDF, 6 pages.
Download Bulletin No 024.
Product Design for Die Casting Manual:
Introduction & Detailed Contents (NADCA publication)
(No. 050) Detailed overview of the contents of the 176-page Product Design for Die Casting manual on optimizing designs for die casting. PDF, 4 pages. Download Bulletin No 050.
The complete NADCA Product Design Manual, above, can be purchased from CWM at discount pricing by registered OEMs & consultants using CWM's Special Discount Order Form in the Resource Center section: Reference Manuals.
Designers & engineers may also wish to reference the following listed elsewhere in the Center:
CWM Die Casting Design & Specification Guide
(No. 0325) Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. Available to registered OEMs by Web Download (see Resource Center section: Design Guides).
3
EVALUATING MATERIALS/ALLOYS
Evaluating Materials & Processes
(No. 020) Introductory overview and guide to optimum materials and alternate process selection. Contains latest physical and mechanical materials properties comparison chart for the most widely used die casting alloys. PDF, 4 pages. Download Bulletin No 020.
NADCA Standards: Aluminum Alloy Data
(No. 071) Al alloy selection, machining and finishing data; chemical composition; material properties and casting characteristics. PDF, 4 pages. Download Bulletin No 071.
NADCA Standards: Magnesium Alloy Data
(No. 074) Mg alloy selection, machining and finishing data; chemical composition; material properties and casting characteristics. PDF, 4 pages. Download Bulletin No 074.
Magnesium EMI Shielding Characteristics
(No. 1001) Outlines EMI/RFI shielding requirements for electronic assemblies. Presents relationships between common measures of shielding, advantages of die castings in general, and mag die castings in particular, for electronic enclosure shielding. Prepared by Norsk Hydro Magnesium. PDF, 2 pages. Download Bulletin No 1001.
NADCA Standards: Zinc & ZA Alloy Data
(No. 075) Zn and ZA alloy selection, machining and finishing data; chemical composition; material properties and casting characteristics. PDF, 4 pages. Download Bulletin No 075.
Primer on Miniature Zinc & ZA-8 Die Casting
(No. 76) Condensed overview for OEM product
designers and engineers on Miniature
Zinc & ZA-8 custom die casting for
the cost-effective production of small,
complex structural components. PDF, 1 page. Download Bulletin No 76.
4
DESIGN SPECIFICATIONS FOR DIE CASTINGS
NADCA Standards: Product Standards Manual Overview
(No. 060) Illustrated condensed overview of the contents of the die casting industry's authoritative "Product Specification Standards for Die Castings" reference manual. PDF, 4 pages. Download Bulletin No 060.
The complete 211-page NADCA Product Standards manual, outlined in the Bulletin above and excerpted in other PDF Bulletins on this page, can be purchased by registered OEMs & consultants from CWM at discount pricing using CWM's Special Discount Order Form (see Resource Center's "Reference Manuals" section: NADCA Product Specification Standards).
NADCA Standards: Introduction to Coordinate Dimensioning & Geometric Dimensioning/Tolerancing
(No. 080) Presentation of "Standard" and "Precision" tolerances as outlined in the latest NADCA Product Standards Manual, plus outline of Coordinate Dimensioning vs the advantages of the GD&T framework for specifying die cast parts. PDF, 8 Introductory pages. Download Bulletin No 080.
NADCA-ADCI Standards Cross-Reference ChartNADCA Standards: ADCI-NADCA Standards Cross-Reference Chart
(No. 063B) Cross-reference chart for former superseded American Die Casting Institute (ADCI) and superseded North American Die Casting Assn. #401 (NADCA) Product Standards and current NADCA Product Standards. PDF, 2 pages. Download Bulletin No 063B.
Designers & engineers may also wish to reference the following listed elsewhere in the Center:
CWM Die Casting Design & Specification Guide
(No. 0325) Updated and expanded 16-page reference to the major design & specification steps that drive the cost and performance of components die cast in Al, Mg and Zn alloys. Among key design and production factors covered: Matching material properties; Die design & construction; Minimizing part porosity; Optimizing part heat transfer; Preplanning post-casting machining, if required; Dimensioning and tolerancing; Flash considerations; Prototyping; and as-cast finish guidelines. Available to registered OEMs by Web Download (see Resource Center section: Design Guides).
5
PROTOTYPING FOR DIE CASTING
Prototyping for Die Casting in All Alloys
(No. 022) Guide to developing optimum prototyping strategies for developing and testing component designs prior to final die casting die construction. Discusses prototyping alloys and processes, including new rapid prototyping technologies. PDF, 4 pages. Download Bulletin No 022.
6
DIE CAST TOOLING CONSIDERATIONS
NADCA Standards: Tooling Checklists for Die Casting Dies
(No. 065) Aid to understanding die caster tooling requirements for optimum part production: Checklists for both new & existing die casting dies to be transfered, based on NADCA Product Standards Manual guidelines. PDF, 2 pages. Download Bulletin No 065.
7
DIE CAST PRODUCTION & SURFACE FINISHING
Surface Finishing for Die Casting Bulletin
(No. 023) Brief overview to surface treatment systems for die cast part protection, decoration and improving component performance, for all alloys: Al, Mg, Zn and ZA. PDF, 4 pages. Download Bulletin No 023.
NADCA Standards: Die Cast Production & Finishing Checklists
(No. 090) Key factors in specifying the production and surface finishing of die cast parts, based on NADCA Product Standards Manual guidelines. Helps assure clearer communication between purchaser and die caster. PDF, 2 pages. Download Bulletin No 090.
Designers & engineers may also wish to reference the following listed elsewhere in the Center:
"Quick Guide" to
Die Cast Surface Finishing
(No.3318) 8-page surface finishing resource for Al, Mg, Zn & ZA-8 parts. Overview of coatings in common use, design tips for best results, comparative cost and performance data for each coating. This CWM Guide available to registered OEMs & consultants by Web Download. Printed copy also available (see Resource Center section: Design Guides).
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