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Examples of Cavitation Effect in Die Casting. G. L. Lockwitz Harley-Davidson Motor Co. Universal Die Casting in 1980’s. Zinc tool Wind Split molding – car hood Cast holding studs Specs H-13 130 ft/sec 46-48 Rc 400 degrees surface of steel Pour about 850 degrees. Universal Failure.

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examples of cavitation effect in die casting
Examples of Cavitation Effect in Die Casting
  • G. L. Lockwitz
  • Harley-Davidson Motor Co.

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

universal die casting in 1980 s
Universal Die Casting in 1980’s
  • Zinc tool
  • Wind Split molding – car hood
  • Cast holding studs
  • Specs
  • H-13
  • 130 ft/sec
  • 46-48 Rc
  • 400 degrees surface of steel
  • Pour about 850 degrees

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

universal failure
Universal Failure
  • Sampling ran 50 shots
  • Took out for die prep
  • Large pit in cover halfabout .020 dia and .050-.010 deep

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

cavitation 50 shots
Cavitation 50 shots

Side view of casting sectionwith cast stud

Gate

Pit in this area

Wind split molding

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

stopped cavitation effect
Stopped Cavitation Effect
  • Welded pit
  • Eyebrow added to gate in line with flow
  • Diverted metal which changed pressure drop
  • Ran 100,000+ with no further problem.
  • Effectively the eyebrow did not allow a local pressure drop in this area to fall below the vapor pressure of the zinc
  • Cavitation inception did not occur

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

the fix change flow pattern

Side view of casting sectionwith cast stud

Diverter in gate

Gate

Wind split molding

The fix – change flow pattern

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

h d rocker cover
H-D Rocker Cover
  • High Cosmetic requirement
  • Early die replacement (25K shots)
  • Cavitation effect on fillets and radii
  • Excellent die tracking by caster
  • Photos taken every 5,000 shots

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

harley rocker cover 89 35 000 shots casting photos
Harley Rocker Cover #89 – 35,000 ShotsCasting Photos

Gated on this side

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

103 rocker 65 000 shots
#103 Rocker – 65,000 Shots

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA

104 rocker 61 600 shots
#104 Rocker – 61,600 Shots

North American Die Casting Association – 114th Metalcasting Congress

CastExpo’10, March 20-23, 2010 Orlando, Florida USA