Die Casting Machine Buyers Guide

Cold Chamber
Die Casting Machine
for Aluminum

Hot Chamber
Die Casting Machine
for Zinc

How to Choose The Right Machine

FORWARD:

This eBook is a continuing work in progress. It is designed for those people who know very little
or nothing about die casting, yet are interested in either starting a die casting business or in the process
itself. The descriptions contained in this eBook are introduced and explained in the most basic form and
in layman's terms, so they can be understood even by those not familiar with die casting.

As time permits, I will add more information and new headings. If you would like to add to this
eBook from your own experience in the die casting industry, please feel free to contact me at
jack@betadiecasting.com

Enjoy, and all the best,

Jack Iwanski
Jack Iwanski

Die Casting Machine Buyers Guide - 1 - Copyright 2016 Jack Iwanski

INTRODUCTION TO DIE CASTING:

Die casting is a rewarding, exciting and profitable business. However, like all businesses it has its
challenges and pitfalls. The key is to identify what they are and how to either overcome them or avoid
them all together. Over my many years in the die casting business I have seen all sorts of approaches to
the die casting business. However, I have seen time and again that buying good quality used equipment
has been the secret sauce to the success of many die casters. Regardless, if it has been during good
times or bad times, the companies who have kept their costs down and have taken advantage of the
benefits of used equipment are still in business and are making a profit. The reason is simple. They
have a competitive edge over those who have gone into deep debt buying extremely expensive, new
machines.

DIE CASTING EXPLAINED:

In the die casting process a mold (called the die) is required. The die is constructed from very
high quality steel specially made for dies. The dies are reusable and are made of two halves. During the
process of die casting, molten metal is injected into the closed die under very high pressure through a
relatively small hole in one half of the die. When the molten metal has solidified sufficiently, the two parts
of the die are opened to expose the actual casting inside. The casting is then removed from the die,
cooled further and then finally trimmed. The trimming separates the gates and runners from the casting.
The gates and runners are incorporated into the die design as a way to distribute molten metal to the
various parts of the die. The trimmed gates and runners are then usually re-melted with new metal also
being added. After trimming, further operations can be performed such as drilling and tapping, powder
coating and assembly of finished components, etc.

APPLICATION:
Die casting is used to make various cast alloy parts in different sizes for a wide variety of
applications. The die casting process is very efficient and can produce large volumes of castings in a
short period of time and has extremely precise repeatability. The flexibility of product types, casting sizes,
a virtually infinite possibility of shapes makes die casting the preferred process for a wide variety of
industries. While die casting dies are more expensive than dies for other forms of casting, such as sand
casting and permanent mold casting or gravity casting, die cast parts offer many advantages such as
very high tolerances, precise repeatability, less porosity, sharply defined parts and a possibility of
textured or smooth surfaces.

Die Casting Machine Buyers Guide - 2 - Copyright 2016 Jack Iwanski

 The flowing chart is a comparison of die casting to other types of casting methods. Each goal is
rated 1 to 3, with 3 being the best and most economical solution. As you can see from the chart, while
the tooling cost is initial more, the Cost Per Part is the lowest of all casting methods.

Casting Methods:
GOAL Die Casting Permanent Mold Investment Casting Sand Casting
Surface Finish 3 2 2.5 1
Complex Shapes 3 2 3 1
Size Accuracy 3 2 2.5 1
Porosity 3 2 2 1
Production Speed 3 2 2 1
Tooling Cost 1 2 1 3
Cost Per Part 3 2 1 2

LIMITATIONS:
With the development of CAD programs, die casting simulation programs and the development of
sophisticated shot monitoring and shot control systems of die casting machines, most limitations for die
casting have been overcome. There are basically only two limitations left. The first is size and weight of
the casting. The size of the physical dimensions of the casting will determine the size of the machine that
is required. However, obviously there is a size limit to this. The item being cast must fit into the mold (die)
with sufficient clearance all around the casting and then mold (die) itself then must fit into the die casting
machine. The mold (die) clearance determining factor is the "distance between tie bars" on the die
casting machine. The mold (die) must be able to fit between these dimensions with reasonable
clearance. So for example, a 600 ton die casting machine usually will have a distance between tie bars
of 737 mm H x 737 mm W (29"H x 29"W). If the mold (die) is bigger than that you will have to move up to
the next size of machine. The largest size of machine ever produced has been a 4000 ton machine with
a "distance between tie bars" of 1780 mm H x 1780 mm W (70" H x 70" W) and a max shot weight of
65kg (143 lbs).

The other limitation is the weight of the casting. For example, a 600 ton die casting machine
usually has a maximum shot weight of about 7 kg (15 lbs). The shot weight is defined as the total weight
of the metal that is injected. The shot weight therefore includes the actual casting plus any runners,
gates and the brisket. The reason for the weight limitation is that the die casting machine must have

Die Casting Machine Buyers Guide - 3 - Copyright 2016 Jack Iwanski

sufficient power and velocity to inject molten metal through the shot sleeve into the die and to fill the die
cavity completely with the metal before the metal starts to solidify. The whole process must be done
within milliseconds and at tremendous pressure otherwise the extreme ends of the mold (die) will not get
filled or will be partially filled. The result will be a scrap castings and wasted effort. While the calculation
of "weight to velocity to time" is extremely complicated, die casting machine manufactures have already
done most of the work for you by "standardizing" this ratio. As such, each machine manufacturer builds a
relatively standardize range of machines with relatively standardized shot weight ranges and relatively
standardized distances between tie bars.

HOW TO SELECT AND BUY A DIE CASTING MACHINE:

There are many things to take under consideration when buying a die casting machine. This
section has been designed to simplify the process of sifting through all the options and selecting the right
machine for your needs.

NEW OR SECONDHAND?
This is the age old question that most people have. However, most people do not realize that
when it comes to die casting machines (as with many other products), manufacturers of these machines
produce several "export versions" depending on which "region" of the world they will be sold to. For
example, die casting machines produced for the North American market will vary greatly in the quality of
materials and technical capabilities when compared to machines produced for "developing" countries.
The reality of the matter is that the North American market is much more "mature" and generally
speaking has much greater requirements and expectations than other developing markets do. In
addition, the level of sophistication, the product technology and budgets for equipment acquisition is
greater as well. As such, many die casting machine manufacturers who have been relatively successful
in producing machines for developing counties have had almost NO success in developed countries like
North America, Europe and other developed markets.

In the world market, these machines have become known as "disposable" machines (possibly the
term came from disposable shavers). Where as a machine made in North America or Europe can be
rebuilt many times over and over due to superior quality steel, such disposable machines have a very
short lifespan of only a few years. After that, it is very hard, if not impossible, to rebuild them properly
since the quality of the metal is very poor.

Die Casting Machine Buyers Guide - 4 - Copyright 2016 Jack Iwanski

For a lack of a better example, the following is an illustration of a vehicle made for the "developing
market" and a vehicle made for a "developed market".

EXAMPLE: WHICH WOULD YOU PREFER TO DRIVE AND BE SEEN IN EVERY DAY??

OR

New Domestic Brand Secondhand World Class Brand

Produced for "Developing Markets" Produced for "Developed Markets"
Price: USD $ 20,000. Price: USD $ 15,000.

The answer to the above question becomes even more obvious when one takes into account the
long term performance of the vehicle, the reliability, the comfort, the amount maintenance, the frequency
of maintenance and finally the resale value. It is very similar with a die casting machine. The question
takes on even more significance when you keep in mind that many of your customers for die casting
projects will want to visit you and see your equipment.

If you have good quality, Brand Name equipment it will be a lot easier to build confidence in
your customer and get the project from them. This is even more so the case with larger orders and
dealing with larger companies. Educated customers today know that if you have good quality, world
class, brand name machines, then there is a much higher chance that castings will be good. It makes
sense.

At the end of the day, good customers (the kind that you want) need to be convinced that you can
do the work and that the work will be done on good equipment. Simply put, seeing good equipment in
you facility, helps them to sleep well at night.

Die Casting Machine Buyers Guide - 5 - Copyright 2016 Jack Iwanski

HIGH PRESSURE DIE CASTING MACHINE TYPES:
There are 3 basic types of high pressure die casting machines.

1) Cold Chamber:
Used primarily for aluminum castings (occasionally
specialized machines for brass and magnesium)

2) Hot Chamber:
Used primarily for zinc and lead (occasionally
specialized machines for brass and magnesium
castings)

3) Multi-Slide:
Used for zinc (occasionally specialized machines
for magnesium castings)

Die Casting Machine Buyers Guide - 6 - Copyright 2016 Jack Iwanski

DIE CASTING MACHINE CLASSIFICATIONS:
There are 3 basic classifications of die casting machines.

1) FULLY AUTOMATIC:
This term means that the die casting machine can perform the whole casting process (mentioned
above) "automatically" without operator intervention or help in the form of manual labor. As such, in order
for the machine to be called "fully automatic" the machine must include all three (3) automatic devices
(referred to in the industry as automation);

a) automatic mechanical ladler

b) automatic mechanical sprayer
c) automatic mechanical extractor.

Die Casting Machine Buyers Guide - 7 - Copyright 2016 Jack Iwanski

2) SEMI AUTOMATIC:
This term means that the die casting machine can perform only one, or at the most two, of the die
casting processes (mentioned above) without manual labor by the operator. The rest of the process
requires manual labor by the operator. In order for the machine to be called "semi automatic" it must
include at least one (1) or at the most two (2) automatic devices; an automatic mechanical ladler, an
automatic mechanical sprayer or an automatic mechanical extractor.

Die Casting Machine Buyers Guide - 8 - Copyright 2016 Jack Iwanski

3) MANUAL:
This term means that the die casting machine cannot perform any of the die casting processes
(mentioned above) automatically. All three processes, ladling, spraying and extraction must be done by
the operator.

While a worker can do all the primary machine processes, to remain competitive it is recommended to
consider a fully automatic machine. The only exception to this would be for a company which does very
small runs or batches of castings. Even in such circumstances, more likely than not a semi-automatic
should be considered. The savings in labor costs and consistency of casting quality is substantial. Not
only that automation allows for more predictability and foresting of production output.

Die Casting Machine Buyers Guide - 9 - Copyright 2016 Jack Iwanski

DIE CASTING MACHINE PROCESSES:
There are 3 primary process involved with make a die casting. They are classified as follows;

1) Preparatory Processes (grey)

Preparatory processes can include by are not limited to die installation, ingot preheating, ingot
melting and holding, fluxing the melt and anything else needed in preparation for the main
machine processes. The following illustrations show a melting/holding furnace as part of both
Manual and Fully Automatic preparatory process.

Die Casting Machine Buyers Guide - 10 - Copyright 2016 Jack Iwanski

 2) Primary Machine Processes (yellow)
Primary processes in die casting include only the immediate processes that are needed for
the die casting machine to produce a casting. There are 3 primary machine processes;

a) Ladling: The process of transferring the molten metal from the furnace to the
shot sleeve. This process can be done manually by the machine operator or
automatically but a mechanical ladling device.
(NOTE: In hot chamber machines the process of transferring the molten metal is
done internally in the machine. As such, no external mechanical device is need).

b) Spraying: The process of spraying die release liquid or compound on one or

both sides of the die before the next cycle starts. This process can be done
manually by the machine operator or automatically but a mechanical spraying
device.

c) Extraction: The process of removing the finished casting from the die before
the next cycle starts. This process can be done manually by the machine operator
or automatically but a mechanical extracting device.

The following illustration shows the full primary machine process.

Die Casting Machine Buyers Guide - 11 - Copyright 2016 Jack Iwanski

 3) Secondary Processes (orange)
Secondary process in die casting can include initial inspection, quenching, trimming and
transport away from the casting machine area using a conveyor.

4) Tertiary Processes
There are many tertiary processes that casting can go through. Among them are surface
finishing, drilling, tapping, painting, assembly, etc.

Die Casting Machine Buyers Guide - 12 - Copyright 2016 Jack Iwanski

WHICH SIZE IS RIGHT FOR YOU?:

Die casting machines are classified based on locking tonnage. For example, an 800 ton machine
has a locking tonnage of 800 tons. Machine specifications vary from brand to brand and even sometimes
from year to year. The following chart shows some basic average specifications gathered from several
brands over a period of time. Of course, some manufacturers have produced sizes of machines which fall
in between the sizes shown below (for example 500 ton) however, the chart is just for basic reference.

Each machine size has a flexible shot range (low and high). The shot range can be switched by
changing the diameter of the shot sleeve and plunger hence the shot weight below shows a range that is
usually possible with each size of machine. A small amount of machines larger than 2500 ton have
been manufactured, however these are very rare and extremely expensive.

Since a die casting machine is selected based on a combination of die size and shot weight, the
following tables show some basic guidelines in selecting the correct size of machine for your needs. The
distance between tie bars is the maximum size of die that will fit into the machine. The die can be single
cavity or multiple cavity.

Average Specifications of COLD CHAMBER (aluminum) machines:

MACHINE 100
250 ton 400 ton 600 ton 800 ton 1200 ton 1600 ton 2000 ton 2500 ton
SIZE ton
Locking KN 981 2452 3923 5884 7845 11768 15690 19613 24516
Force ton 100 250 400 600 800 1200 1600 2000 2500
Distance
mm 384x384 508x508 610x610 737x737 914x914 1000x1000 1143x1143 1300x1300 1450x1450
Between
inch 15x15 20x20 24x24 29x29 36x36 39x39 45x45 51x51 57x57
Tie Bars
Shot kgs 0.6 -1.8 1.3 - 2.6 2.5 - 4.7 4.3 - 7.1 7.1 - 11.2 9.7 - 23.4 10.3 - 28.6 15 - 33 18 - 35
Weight lbs 1.4 - 4.0 2.9 - 5.7 5.6 - 10.3 9.5 - 15.6 15.6 - 24.6 21.4 - 51.6 23 - 60 33 - 73 40 - 77
Shot weight is based on Aluminum alloy

Average Specifications of HOT CHAMBER (zinc) machines:

MACHINE
50 ton 75 ton 100 ton 150 ton 200 ton 250 ton 300 ton 350ton 400 ton
SIZE
Locking KN 490 735 980 1471 1961 2452 2942 3432 3923
Force ton 50 75 100 165 190 250 300 350 400
Distance
mm 335x335 365x365 406x406 470x470 490x490 520x520 540x540 560x560 620x620
Between
inch 13.2x13.2 14.3x14.3 16x16 18.5x18.5 19.3x19.3 20.5x20.5 21.3x21.3 22.8x22.8 24.4x24.4
Tie Bars
Shot kgs 1 1.4 2 2.87 3.5 4.24 4.5 4.97 5.7
Weight lbs 2.3 3.14 4.5 6.32 7.76 9.35 9.9 10.96 12.5
Shot weight is based on Zinc alloy

Die Casting Machine Buyers Guide - 13 - Copyright 2016 Jack Iwanski

WHICH IS THE RIGHT SIZE FOR YOUR SPECIFIC PROJECT?
Most die casting projects fall into one of these two categories. This is a simplified explanation, but
it covers most projects you will encounter. This table explains how to find the right machine for a specific
project.

Project Categories:

PROJECT TYPE HOW TO FIND THE RIGHT SIZE OF MACHINE

If it is a new project and no die has been made yet, then a local die maker will be
the best person to tell you the shot weight and size of the final die. Once you have
New Die
that information, he will be able to suggest to you the size of machine needed OR
you can use the charts on the previous page.
If the die has already been made and has been run by someone else, the owner of
the die can tell you the size of machine that was used. If not, then perhaps you
Existing Die
can look at the drawing of the die and then consult with a local die maker OR you
can use the charts on the previous page.

WHAT IS THE ESTIMATED PRODUCTION OUTPUT?

This question is a somewhat more complicated question to answer. But there are guidelines
which help greatly. Most die casting machine manufacturers (not all) provide dry cycle times for their
machines. A dry cycle is the amount of time needed for the machine to perform the whole casting
process from bringing to end WITHOUT molten metal being added and WITHOUT cooling time of the
casting. Generally speaking, the larger the machine the slower the dry cycle time. The reason for this is
that larger castings are made on larger machines. The smaller the casting, the less time it needs to
solidify and so the cooling time (also known as set time in some parts of the world) become less of a
factor. With very small castings it is not a factor at all. It all depends on the casting size and weight.

It is not possible for die casting machine manufacturers to give figures for actual cycle time
without sufficient information about each proposed casting and the amount of cavities in the die.
However, these figures are obtainable from either a die maker or by using die casting simulation
software and vary greatly from project to project. Such figures are important because they will tell you
how much time it would take for the casting(s) to solidify in the cavity(s) after injection and before the
machine can open the die and the casting(s) can be removed. So, as you can see, at best, die casting
machine manufactures can only provide dry cycle times.

Die Casting Machine Buyers Guide - 14 - Copyright 2016 Jack Iwanski

 To calculate the actual cycle time you will need to add cooling time to the dry cycle time
provided by the machine manufacturer. Here is a simple way to calculate Estimated Production Output
using only dry cycle times, (but be sure to add cooling time to get a Final Production Output figure).

EXAMPLES:
The following examples are based on a die casting machine which has a 4 second dry cycle. Keep in
mind this is only theoretical and does NOT include cooling time.

ESTIMATED PRODUCTION OUTPUT CALCULATION (Dry Cycle) - SINGLE CAVITY DIE

=====================================================================
60 seconds (1 min) divided by 4 sec. = 15 castings per minute
15 x 60 minutes = 900 castings per hour
900 x 8 hours = 7,200 castings per 8 hour work day

ESTIMATED PRODUCTION OUTPUT CALCULATION (Dry Cycle) - 4 CAVITY DIE

================================================================
60 seconds (1 min) divided by 4 sec. = 60 castings per minute
60 x 60 minutes = 3,600 castings per hour
3,600 x 8 hours = 28,800 castings per 8 hour work day

WHICH IS THE RIGHT BRAND?

There are many manufacturers of die casting machines in the world. However, our many years of
experience have shown, over and over again, that the best quality machines are recognized brand
names manufacturers and originate from North America, Europe and Japan. As well, do not be too
focused on the age of the machine. Due to their construction, and unlike most machines, die casting
machines last a very long time. In addition, the technology has not changed too much over the years.
Unless you plan to make very high end castings, most well made used machines should be sufficient for
most applications. There are some good deals to be had slightly older machines.

Die Casting Machine Buyers Guide - 15 - Copyright 2016 Jack Iwanski

WHAT IS A REALISTIC BUDGET?
While of course, everyone would like to spend the least amount of money on capital equipment
such as a die casting machine, generally speaking, you can use the follow basic guidelines when it
comes to comparing prices of new and used machines. The reason for the price range of secondhand
machines is the age and the condition.

Price Comparison (Secondhand to New):

SECONDHAND NEW PRICE OF SECONDHAND
MACHINE TYPE MACHINE TYPE COMPARED TO NEW
Secondhand Machine New Machine
10% to 30% of new price
Brand Name - Good Quality Brand Name - Good Quality
New Machine
Secondhand Machine
Off Shore - Low Quality - 40% to 60% of new price
Brand Name - Good Quality
Disposable
This comparison takes under consideration the cost of machine plus cost of automation equipment and shipping.

SOME EXAMPLES OF USED AND NEW MACHINE PRICES:

460 ton Buhler 650 ton Toshiba

Price Used: USD $ 65,000. (1991) Price Used USD $ 85,000. (1994)
Price New: USD $ 500,000. (approx) Price New: USD $ 600,000. (approx)

Die Casting Machine Buyers Guide - 16 - Copyright 2016 Jack Iwanski

WHERE SHOULD YOU BUY A USED MACHINE?:

When considering the purchase of a used machine, ultimately you have two basic choices.

BUYING PRIVATELY:
The first choice is to buy privately from a die casting company. However, when you think about it,
this choice is very often limited, actually more so then you would expect. First of all, by calling from die
caster to die caster it is hard to locate the right machine for your needs.

Secondly, there are used machinery dealers like my company, in which it is their business to call
and keep in contact with all die casters on a regular bases and find out if they have machines for sale.
For example, our company is in touch with just about every die caster on the planet. When we do find a
good machine, we snatch up before it even sees daylight. Therefore, your chances of finding a good
machine just phoning around becomes very remote.

BUYING FROM A DEALER:

The second choice you have, is to buy from a die casting machine dealer. There are two types of
dealers in the world stocking and non-stocking. No-stocking dealers accumulate lists of machines
available for sale. They offer these for sale to everyone and they usually make about 10% as a selling
commission from the owner of the machine. There are 3 problems with this type of business model;

1) Non-stocking dealers sell machines that they have not purchased with their own money. As
such, they take no responsibility for these machines. They basically sell and run.

2) Non-stocking dealers have no stock on hand and so they can disappear very quickly. They
have no big, heavy machines to move which takes time, effort and money.

3) Non-stocking dealers offer machines that a stocking dealer like my company already passed
up or refused to purchase. When we pass on a machine there must be a very good reason.
Non-stocking dealers usually offer the leftovers after stocking dealers pick over the good
ones.

Die Casting Machine Buyers Guide - 17 - Copyright 2016 Jack Iwanski

Here is an example comparing a Non-Stocking Dealer to Stocking Dealer;

Non-Stocking Dealer Offers Leftover Stocking Dealer Offers The Best

Machines Machines

- Does not invest any of his own money in
the machine.
- Takes no responsibility in after-sale.
- Here today (but can disappear tomorrow).
- Invests own their money in the machine.
- Takes pride in responsibility in after-sales.
- Business is built on long term
relationships.

MORE INFORMATION:

As mentioned this eBook is a work in progress. If you would like more reference material, check
out these links;

Learning Center: http://www.betadiecasting.com/learning-center/

An assortment of educational videos and other die casting related information intended to further
understanding and knowledge about the die casting business worldwide.

Business Center: http://www.betadiecasting.com/business-center/

Various articles that are presented in the form of short "series" that are designed to help you improve
your business and to avoid many of the pitfalls that are common in business and especially the die
casting business.

Machine Inventory: http://www.betadiecasting.com/

A huge selection of machines in stock and ready to go.

Die Casting Machine Buyers Guide - 18 - Copyright 2016 Jack Iwanski