Rocklin Manufacturing Blog


Posted by Ross Rocklin in Rocklin Mfg on 10/30/2018

Having just completed the Die Casting Congress & Exposition in Indianapolis, it was clear that the Rocklinizer Carbide Application Equipment delivers wear protection solutions to some of the biggest problems facing die casters.  But what are those problems, and how does the Rocklinizer solve them?  

Rocklin Manufacturing at Die Casting Congress & Exposition Show in Indianapolis

First, we’ll delve into the top 5 issues die casters face and how the Rocklinizer alleviates them. Then, we’ll list the top 5 advantages of the Rocklinizer for die casters.

  1. Heat Checking: This is probably the most frequent cause of failure of a die casting die, i.e. thermal fatigue caused by the alternating heating and cooling of the die surface. Small cracks eventually form a closed network, and become so large that the casting metal will flow into the steel surface below. Then you’re stuck resinking or remaking the die entirely - an expensive proposition. But, you can solve this issue by applying tungsten carbide with the Rocklinizer to the areas most prone to heat checking on a preventative maintenance basis. If you’re already facing large heat checks on your die, you can first use a sanding drum to remove them. Then, simply apply tungsten carbide using our rotary applicator from .0001” to approximately .005”, controllable within .0001” by machine setting.
  2. Wear on Gates, Vents & Runners: These wear areas stay much cleaner when they’ve received tungsten carbide. Minor cracks in a die can be covered as long as they haven’t been allowed to progress to a width greater than approximately .002”.
  3. Soldering: Soldering of the zinc or aluminum casting material to the die surface is also a cause for rejection of many castings. Treatment prior to a production run has eliminated soldering at gates, vents, parting lines, and the die cavity where molten metal has a tendency to solder to the cavity.
  4. Ejector Pin Flashing: This can be eliminated if the die is in fair condition before treatment. Tungsten carbide applied to the ejector pin about one inch back from the face of the cavity has had good success.
  5. Galling or Seizing of Cores: The thermal expansion of zinc and aluminum die cast metals is much greater than that of the steel core. The metal shrinks onto the cores, thus resulting in extreme pressure at the core section. The cores with the carbided surface make the lubricant or die releasing agent adhere better to the steel, thereby providing a nice finish on the cast parts.
Die Casting Die

Now that we’ve addressed the biggest problems, what are the biggest benefits of “Rocklinizing” in a die casting facility? Our customers realize:

  1. LESS Machine Downtime
  2. LESS Operator Idle Time
  3. LESS Die Removal and Reinsertion Time
  4. LESS Die Maintenance
  5. MORE Die life, Productivity, and Cost Savings
Rocklinizer Model 950

To learn more about using the Rocklinizer in die casting or for a wide range of other wear reducing and gripping applications, give us a call at 800-255-6046.

 

Tags: Rocklinizer , Carbide Application Equipment , Die Casting , Congress & Exposition , Carbide Application , Trade Shows , Exhibitions , Conferences , Heat Checking , Thermal Fatigue , Tungsten Carbide , Soldering , Ejector Pin Flashing , Galling

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