WHAT: Front Steering Knuckles for Jaguar Vehicles

PROBLEM: Steering knuckles are integral to the steering and braking mechanisms for cars. They traditionally are made by forging or as iron or steel components. Automaker Jaguar wanted to switch to aluminum components because of their weight savings. The initial process they pursued failed, and with production in jeopardy, they turned to a supplier that had experience making aluminum knuckles, although not as large or complex as Jaguar's component.

SOLUTION: The supplier statistically proved static mechanical properties, confirmed chemical analysis and produced test data to prove their process and material. Both the supplier and Jaguar rigorously tested the new parts in the lab and in the cars with punishing driving tests. The castings survived each time. The supplier installed the necessary equipment to make the first aluminum squeeze cast knuckles. This included a DCM, built for a P2000 process, a melting furnace, robotics, and an X-Ray facility to enforce acceptance standards.

ALLOY: Aluminum Alloy A.356.2 (T6)

WEIGHT: 9.7 lb.

CASTER'S COMMENTS: "This was a project that necessitated a 'right first time' result. Failure would have damaged our reputation and would have stopped the manufacture of two car lines at Jaguar. The customers, both at the machinist and the vehicle manufacturer, are delighted not only with the performance of the casting, but also with its physical appearance. The success immediately led to a second order. We are looking to apply the same technology to other new customers throughout Europe."

WHAT: Right Hand and Left Hand Reflector for Minivan

PROBLEM: An automotive reflector is used in a fog light assembly. In the past, the lights were a combination or a plastic housing assembled with an aluminum casting. Both parts had to be metalized by depositing aluminum on the reflective surfaces. The die cast part was the reflector and was also used to support and adjust the light on the minivan. The customer wanted to make an aluminum reflector as a stand-alone assembly to reduce the piece cost and the assembly costs.

SOLUTION: The new light is a die casting with the reflective optics, the pivot bosses, and height adjustment built into the casting. There are two single cavity dies, one for the right hand and one for the left hand. Each die has four slides that cast the external detail used in assembling and supporting the fog light. The part is leak-proof, has thin walls to reduce weight, has strong pivot bosses, and meets critical tolerances to seal the bulb and direct the light's beam.

ALLOY: Aluminum 383

WEIGHT: 0.66 lb.

CASTER'S COMMENTS:"We have been successful in meeting the part specifications with a cost savings of 14.5 percent per assembled unit."

WHAT: L4 Cam Cover for Engine

PROBLEM: GM Powertrain wanted to replace the existing plastic cam cover used on its in-line 4 engines. The camshaft cover provides a seal with the cylinder head to prevent oil leakage. Its additional functions include noise suppression, oil fill port, ventilation, and spark plug access. The goal was to further improve structural integrity at elevated temperatures, sealing to prevent oil leakage, NVH performance and the removal of condensed water on the top surface.

SOLUTION: The supplier developed an innovative die design and die casting process using a three plate die with a central gating system (instead of side-gating) at the central coil mount bores. This new design allowed better flow and solidification, which reduced poor fill, porosity, distortion and internal stress. Die cast aluminum A380 allows thinner wall sections and shorter coil mount bores as well. Aluminum avoids the part distorion and degradation that plastic suffers at high temperatures. The new design provides better sealing and noise suppression.

ALLOY: Aluminum 380.0

WEIGHT: 9.72 lb.

CASTER'S COMMENTS: "The newly designed aluminum cam cover to replace plastics provides both challenges and opportunities to the die casting industry. The greater strength of aluminum allows applying additional load on the cover. In this case, stake pins are cast for riveting baffle plates. Together with fewer fasteners and aluminum's recycle ability, total manufacturing cost is reduced."

WHAT: Rear Sub-Frame for Auto Body

PROBLEM: The rear sub-frame serves as part of the skeleton of the automobile. This part demands high strength, including in sections joined by welding. Conventional die casting methods did not provide the strength and reliability of demanding conditions and also limited weight reduction of the part.

SOLUTION: The supplier's team developed a new High Vacuum Die Casting Technology to produce a stronger yet lighter-weight sub-frame. The technique allows the die to be filled under a very high vacuum condition to produce castings with very little gas inclusion. They use a specially designed holding furnace, which decreases debris and gases that cause weakening in a casting. Use of special aluminum alloys also enhanced the strength and toughness of the castings.

ALLOY: Aluminum Silafont36

WEIGHT: 20 lb.

CASTER'S COMMENTS: "The new High Vacuum Die Casting Technology reduced the weight of the sub-frame by 38 percent compared to steel stamping but provided the strength to absorb impact. The parts produced by this new technology are connected to another aluminum part by MIG welding."

WHAT: Backbone (Left and Right) for Dewalt 18 Volt Cordless Nail Gun

PROBLEM: Black & Decker and the die caster worked on creating lightweight left and right backbone parts to serve as the skeleton of a new product development, the Dewalt 18 Volt Cordless Nail Gun. The backbone had to support all of the Nail Gun's internal and external components.

SOLUTION: It was important that the parts be lightweight but have superior casting integrity, along with the high elongation provided with AM60. The parts were competitively produced using hot chamber technology and minimal machining on dedicated machine tooling.

ALLOY: AM60

WEIGHT: Left: 0.214 lb. Right: 0.284 lb.

WHAT: Z06 Corvette Engine Cradle

PROBLEM: Until now, either steel or aluminum has been used in the engine cradle. To reduce weight in GM's Z-6 Corvette engine cradle, the decision was made to develop magnesium chassis components. The automaker's goal was to reduce their car's weight, improve fuel economy, provide better weight balance and improve steering.

SOLUTION: The supplier used a new high-temperature AE44 magnesium alloy and high-pressure die cast process to create a 24-pound engine cradle with a weight savings of approximately 33 percent. The single-piece magnesium design also improves assembly and provides structural integrity. By allowing integration of the steering gear attachments into the cradle, the design also improved vehicle responsiveness. ALLOY: AE44 Alloy from Norsk Hydro Magnesium

WEIGHT: 24 lb.

CASTER'S COMMENTS: "This is the auto industry's first magnesium high pressure die cast chassis component. The addition of magnesium as a viable option opens the door for additional weight savings opportunities in vehicle parts that were previously not possible, including chassis and power train."

WHAT: Low Voltage Waterproof Wire Connector

PROBLEM: Low voltage wire connectors have always needed at least a wire stripper and possibly pliers to squeeze the connector together. Connectors also need true long-term waterproofing. For this new design, the goal was to eliminate the tools required to make a connection, to make it easy to use, foolproof, cost efficient and waterproof.

SOLUTION: The design used a non-conductive plastic housing to rotate the conductive zinc shaft, which strips the wire insulation, contacts the conductors and moves the non-hardening silicone grease with a built-in sweep feature. The advantages of the new design are fewer parts; lower tooling, assembly and part costs; improved quality and usability; and a product that is waterproof, and not merely water resistant.

ALLOY: Zamak 7 WEIGHT: .006 lb.

CASTER'S COMMENTS:"We believe this to be a new use for a zinc die casting. Such a miniature casting can be difficult to fill because of its extremely thin walls and unique shape. This 4-cavity mold runs in a miniature high speed 2-inch by 2-inch machine. NADCA's PQ2 and Castview software was helpful in the design of the gates and runners."

WHAT:IMA Stabilizer Link for OEM Automotive Suspension

PROBLEM: The supplier was welding precision stamped rings onto the end of stabilizer link rods. Many things made the process costly. The ring needed an expensive secondary sizing operation and the rod was costly because of the close tolerances required to meet the correct capability for length after resistance welding. Another cost included shipping for plating the parts after welding.

SOLUTION: In the new die cast process, pre-plated and knurled rods with die cast rings on the ends are placed directly into the die and the zinc is cast directly onto the knurls. After casting, the part is directly transferred to final assembly equipment and completed.

ALLOY: Zamak 5

WEIGHT: 7.8 ounces

CASTER'S COMMENTS: "Zinc is much less expensive than the stamped ring. We saved over 20 percent in our material cost. By using pre-plated rods, we reduced inventory and shipping costs. The automated IMA die casting process is also highly versatile compared to the welding process. By changing the rod and housing orientation, we are able to make a completely different part for another application."

WHAT: Cover for the base of a funeral casket handle

PROBLEM: The previous handle cover was a utilitarian-looking steel stamping without the aesthetics many customers would prefer. Used temporarily during funeral services and re-used in most cases, the part also needed to be durable for extended use.

SOLUTION: The die caster developed this cover to make it look more ornamental after it is attached to the casket. He patterned the zinc die casting after DaVinci's Last Supper and created the model on computer by inputting a scanned 2D image and using new, advanced software to give it 3D depth. This allowed the use of a uniform wall, reduced weight and avoided heat sinks, which helped maintain the integrity of the artwork's faces. It also allowed the die caster to have a faster lead time and be competitive with world suppliers. The part was manufactured in house using CAD/CAM and CNC machining and has an electro-plated finish. In addition, the die cast part is extremely rugged, looks new for a long time and can be recycled.

ALLOY: Zamak 3

WEIGHT: 1.41 lb. (wt. of part)

CASTER'S COMMENTS: "The product is our own and we chose it as a superior replacement to the steel stamping. Although the cost is greater, there is no comparison between the two parts when one considers aesthetics. The extra cost is often secondary to our customers in consideration of what it is used for. We feel that our die cast part shows our customers that for many cosmetic applications, die casting is beyond comparison with other manufacturing methods."

Bezels for controllers and network hardware F5 Networks, Inc., Liberty Lake, Wash., created bezels and faceplates for controllers and other network hardware with core inserts to allow for different connector arrangements and product variations, including doors for power supply access. Designed in two sizes for equipment going in standard computer racks, the die cast parts replaced previously used plastic pieces. The aluminum and zinc die cast parts provided greater structural rigidity, the ability to mold all the features needed in a single piece and they eliminated the need to coat parts to provide EMI shielding.."