NADCA Standards for High Integrity

and Structural Die Casting Process

NADCA Standards for High Integrity and Structural Die Casting Process
2021
8th Edition

3250 N. Arlington Heights Rd., Ste. 101

Arlington Heights, IL 60004
tel: 847.279.0001 • fax: 847.279.0002
publications@diecasting.org
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2021

NADCA Publication #403

NADCA Standards for High Integrity and
Structural Die Casting Process
Section Content
Number

1 High Integrity High Pressure (HIHP) Casting Processes

Heat Treatment & Temper Designations for High

2 Vacuum, Squeeze and SSM Casting
Chemical, Mechanical & Physical Properties of High
3 Vacuum, Squeeze and SSM Casting

4 Engineering and Design: Coordinate Dimensioning

5 Engineering and Design: Geometric Dimensioning

Engineering and Design: Additional

6 Specification Guidelines

7 Quality Assurance

8 Commercial Practices

High Vacuum, Squeeze and Semi-Solid

9 Casting Examples

10 Glossary

i
 Overview

Weight reduction has been a major focus of many industries over the past decade or
more. The automotive industry for example has concentrated on downsizing and light-
weighting to meet governmental, marketing and performance pressures. To accomplish
targeted weight reductions, the carmakers have increasingly looked to the use of alumi-
num and magnesium alloys. Additionally, the automakers, along with other industries,
are investigating new and developing processes for casting aluminum and magnesium
components. These processes offer near-net shape capability, improved strength, and
excellent ductility, along with the pricing structure required to meet automakers’ needs.
The three processes that have already met target production needs and, as the technol-
ogies further develop, are expected to continue to expand their applications, are High
Vacuum Die Casting, Squeeze Casting and Semi-Solid Metal Casting (SSM).
Each of these three processes has been through a typical development process,
including examination and improvement by the academic community, the normal trial
and error of the first entrepreneurs and, finally, the risk acceptance by the first practitio-
ner and consumers. Each process has now progressed beyond this initial stage and are
now rightfully classed “production ready” and a number of parts produced by each
process are incorporated in current automotive models around the world, as well as be-
ing used by a number of other industries.
While all of the current squeeze casting applications utilize aluminum alloys, both alu-
minum and magnesium components are being commercially produced by high vacuum
and semi-solid casting. In addition, copper, zinc, and to a limited degree, ferrous alloys
have also been cast in each of these processes, but none of these other alloys are be-
ing produced on a commercial basis. Further, research work is ongoing on a variety of
materials and process improvements around the world. However, since aluminum and
magnesium have played a major role in the development of these three processes, what
follows is most applicable to the high vacuum, squeeze, and semi-solid casing of these
two metals.

Process Similarities
Although each of the three processes differ in the details of how the castings are
produced, they are all similar in that they are seeking to produce high quality castings
containing minimal levels of gas porosity, shrinkage porosity, and other defects, and
each are capable of being fully heat treated without blistering. Although there are
significant differences between the three processes, all have a number of similarities
as outlined below:
• Alloys – The alloys that are used for these three high integrity casting processes
are all chosen to be capable of generating an excellent combination of strength
and ductility. For the aluminum alloys, this means choosing alloys containing low
levels of iron (generally ≤0.2% Fe).
• Metal Quality – To generate excellent mechanical properties, it is necessary that
the metal quality be very high. Before casting, it is common for the alloys to be
filtered and treated to minimize dissolved gases, oxides and all other non-metallic
inclusions, and that handling techniques be used that treat the metal gently as it is
transferred to the casting machine (to minimize oxide inclusions).

ii NADCA Standards for High Integrity and Structural Die Casting Process / 2021
 • Casting Machines – All three processes use die casting machines that are capable
of injecting the metal into the cavity under closely controlled conditions. There are
two possible variants (although in each case the indirect process is more common
commercially):
o Direct – The pressure is applied directly to the metal (liquid or semi-solid) from
a hydraulically activated source. Hence processes utilizing this approach are
referred to as direct squeeze casting or semi-solid forging (SSF).
o Indirect – Pressure is transmitted from the hydraulic source through a runner
system to the metal being solidified in a die cavity. This approach is common for
all three processes.
• Heat Treatment – Controlled thermal treatments can be used to develop excellent
strength-ductility combinations.

Process Variants
There are also significant differences between the three processes, which are de-
scribed below. In addition, each of the three processes have dissimilar histories, both
in time and in the maturing cycle, and a short history of each process is also pro-
vided.

1. High Vacuum Die Casting

Vacuum has been applied in die casting for some time, but it was only in the
1990s that very high vacuum in combination with new alloys and best practices
regarding metal quality, process controls, etc. offered the ability to produce high
integrity structural die castings for car bodies that could be welded, heat treated
and were crash worthy. The high vacuum die casting process maintains the high
injection velocity used with conventional die casting, but reduces the air pressure
within the die cavity to 50 milli-bars or less (5% of an atmosphere), so there is
little air to become entrapped in the castings. Specially designed fan or “antler”
gating systems in combination with sophisticated die designs, especially with
respect to thermal management of the die, generates a single homogeneous metal
front while filling the die, to minimize the entrapment of any air, lubricant or con-
taminants remaining in the cavity and avoid oxide inclusions from joining metal
fronts. Several heat treatment technologies and many different alloys are now
available to meet the high property requirements of car companies, producers of
recreational vehicles, marine applications, etc. Parts range from less than a pound
(450 gms) to over 30 lbs (14 kg) and from just a few inches (>25 mm) long to 60
inches (1.5 meters) long. Typical wall thicknesses are in the range of 0.08 to 0.16
inches (2 to 4mm).

2. Squeeze Casting
The principle that pressure applied to molten metal during solidification will en-
hance its properties has been known for over 150 years. In fact, the original
patent was applied for in England in 1819. The Russians have used direct squeeze
casting for piston manufacturing for over 100 years. However, the process did, in
effect, lie somewhat dormant until the 1970’s when first, direct squeeze casting

NADCA Standards for High Integrity and Structural Die Casting Process / 2021 iii
 was reactivated for several defense applications as well as for pistons, and later
indirect squeeze casting was used to make aluminum automobile wheels for a
Japanese car manufacturer.
The fact that squeeze casting could provide essentially porosity free castings
surfaced at the same time that the auto industry was searching for ways to reduce
weight at minimum cost. The process swept rapidly across Japan over the next
ten years replacing iron parts, i.e., control arms, steering knuckles, cylinder liners,
pistons, engine supports, etc. A number of other industries also took advantage of
the unique character of squeeze casting, i.e., bicycle, air conditioning, valve and
pump, etc.
Direct squeeze casting was first introduced to the US by Doehler-Jarvis in the
1960’s, and has been used since the late 1980’s in the United States and Europe
for piston manufacture, particularly ceramic inserted. Then in 1990 the first indirect
squeeze operation was installed in the United States. Today there are squeeze
machines installed worldwide producing a variety of components ranging in
size between as little as 3.5 ounces (100 grams) to a crossmember weighing 31
pounds (14 kilograms).

3. Semi-Solid Metal Casting

Semi-solid metal (SSM) casting is different than all other casting processes, as
instead of using a fully liquid feed material, it uses a feed material that is partially
solid and partially liquid. SSM casting has also been practiced in some form for
over 100 years. However SSM casting as we know it today evolved out of a series
of studies performed by Professor M.C. Flemings and his students at MIT in the late
1960’s and early 1970’s. It was noted that when the normal dendritic microstruc-
ture was modified to a non-dendritic, spheroidal structure, the resulting material
having a remarkably low shear strength even at relatively high solid fractions - it
became thixotropic.
The resulting quality and integrity of parts formed using the semi-solid process
were evident in improved mechanical properties. Further, it became obvious that
the process could be applied to a number of different alloy systems. The original
MIT patent rights were eventually obtained by Alumax, Inc., a primary alumi-
num producer, now a part of Alcoa. Beginning in the very late 1980’s and early
1990’s, Alumax started producing semi-solid parts for automotive applications.
When key original patents expired in 1992, the commercial application of the
process rapidly expanded around the world.
The semi-solid process originally commercialized by Alumax involved the produc-
tion of a pre-cast billet having the globular semi-solid microstructure. Slugs cut from
these billets were re-heated to the semi-solid temperature range for casting. This
process is referred to as thixocasting. Although thixocasting achieved commer-
cial success, and is still in use today, the pre-cast billet approach was considered
costly by many end-users. Therefore, alternate approaches to semi-solid casting
have been developed, where the semi-solid slurry is generated directly from the
liquid. These processes are referred to as rheocasting, and there are a number of
different variations in commercial production or under development around the
world. In addition, a specialized semi-solid process for magnesium alloys called

iv NADCA Standards for High Integrity and Structural Die Casting Process / 2021
 thixomolding has been commercialized, and this process uses a press similar to
an injection molding machine. All three processes (thixocasting, rheocasting and
thixomolding) are in commercial production making parts for a number of markets,
including automotive, motor cycle, electronics, aerospace and sporting goods.
Similar to squeeze casting, semi-solid machines are installed around the world pro-
ducing aluminum and magnesium parts ranging in size from a tenth of an ounce
(few grams) to more than 22 pounds (10 kilograms).

Conclusion
All three processes, High Vacuum Die Casting, Squeeze Casting and Semi-Solid
Metal (SSM) Casting, have demonstrated the ability to produce high integrity com-
ponents for a wide range of industries. These processes are being practiced, in some
form, in Europe, North America and Asia. High Vacuum Die Casting is today the most
practiced process of those and now very fast growing in all regions of the world.
More and more OEMs are either purchasing components made in high vacuum die
casting or are (also) producing them, and a significant supply base is now available
for such components and competitive prices. There are still some economic hurdles to
jump before either of the other two processes have universal acceptance; however,
significant strides in cost reduction have been made over the past several years and
further gains can be expected in the future.

Acknowledgements
A special thanks to the following individuals for their knowledge, time and effort used
to revise this book to the 8th edition:
• Hal Gerber • Max Gondek • William DiBacco
• Martin Hartlieb • Garvey Madden
• Adam Kopper • Ryan Winter
• Steve Midson • Alex Monroe

Revision Changes
The 8th edition of this book is a minor update with the following changes:
• Revised wording on the high integrity high pressure casting process to be more
clear/inclusive in section 1
• Added information about precipitates that form in die casting alloys in
section 2
• Corrected information about T6 and T7 heat treatments in section 2
• Updated tables to include generic alloy names in section 3
• Removed Contech results from section 3
• Revised draft guidelines in section 4
• Added information for GD&T use in die casting in section 5
NADCA Standards for High Integrity and Structural Die Casting Process / 2021 v
 • Added information on ejector pins in section 6
• Separated simulation into two parts (lean manufacturing and simulation) in
section 7
• Added a paragraph on structural quality in section 7
• Revised wording for die ownership and maintenance practices in section 8
• Fixes to typographical errors and minor clarification to existing information
made throughout the book

vi NADCA Standards for High Integrity and Structural Die Casting Process / 2021
 1
High Integrity High Pressure Casting Processes section

Section Contents Page

Introduction 1-2
1
1 High Vacuum 1-5
2 Squeeze Casting 1-7
3 Semi-Solid Casting 1-7
4 Comparisons of High Vacuum, Squeeze, SSM and Other Casting Process 1-12
Table 1-2a: Product Characteristics – Strength & Integrity Factors 1-12
Table 1-2b: Product Characteristics – Dimensional & Complexity Factors 1-13
Table 1-2c: Product Characteristics – Machine & Tooling Factors 1-14
Table 1-2d: Product Characteristics – Casting Factors 1-15
Table 1-2e: Economics – Process & Product Cost Factors 1-16

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-1
 High Integrity High Pressure Casting Processes

Introduction

High Integrity High Pressure (HIHP) casting processes represent a relatively new range of casting
processes which combine the near-net shape benefits associated with traditional high pressure
die casting with novel approaches to produce high integrity, heat treatable, weldable, light alloy
components. In general, high integrity high pressure casting processes can be categorized as ones in
which metal in either a fully liquid or semi-solid state is injected in either a non-turbulent manner
or in a very controlled way with high vacuum into a re-usable steel die, and subsequently held
under high pressures throughout the solidification process to produce sound, fully heat treatable
components. As such, HIHP casting processes compete against other traditional premium quality
shaping processes such as forging, low pressure permanent mold casting and its variations, dry-
sand molding and fabrication, for the production of lightweight structural components. HIHP cast
parts can be found today in safety critical automotive suspension applications, recreational goods,
and car body structures and other engineered structural applications.
In order to satisfactorily produce components which comply with the above criteria, HIHP
casting processes must solve the several critical issues of 1) entrapped gas, 2) solidification
shrinkage voids, 3) hydrogen porosity, (Fig. 1-1a, 1-1b & 1-1c) and 4) various sorts of oxides and
other inclusions. Gas porosity occurs when the air pre-existing in the cavity or shot system or
gas that might evolve due to the break-down of lubricants and coatings in the system becomes
entrapped in the casting during the filling process. Gas entrapment is avoided by two separate
methods. First, is by controlling the injection process so that the die is filled in a non-turbulent
manner (see the left hand casting in Figure 1-2). Alternatively, high density raw material,
engineered vent area locations, overflow masses, and applied vacuum within the cavity can be
utilized to remove moles of gas that could potentially become trapped during the rapid, high
pressure fill.
In the conventional high pressure die casting process all remaining unvented, trapped gases are
squeezed so effectively during fill and solidification that they are barely visible; even under x-ray
examination. For most applications heat treating is not required, so these small gas bubbles cause
no quality concerns and go unnoticed. When heat treatment is required to alter the mechanical
properties of the casting though the gas expands upon heating, creating localized regions of
stress which exceed the yield stress of the heated alloy, resulting in blistering. These blisters not
only present an unacceptable surface, but they also degrade the mechanical performance of the
components. By preventing gasses from being trapped during the filling process, high vacuum,
squeeze and SSM castings can be heat treated. In a similar manner, the lack of entrapped gases
also allow these castings to be welded or joined by other fusion methods without blistering or
out-gassing.
While solidification shrinkage porosity represents a more tolerable issue, since it does not
directly impact the heat treatability of the components, it too, represents regions of weakness
in the cast components and must be avoided. It is the application of high pressure, especially in
SSM and Squeeze (to a slightly lesser degree in high vacuum die) casting, which is important in
eliminating solidification shrinkage, since it forces additional liquid metal into the mold as the
casting is solidifying, feeding both macro- and micro-shrinkage porosity.
A principle advantage of HIHP casting is the ability to feed solidification shrinkage until late in
the freezing process, aided by cavity metal pressures which often exceed 10,000 psi (5000-8000 psi
in high vacuum die casting). This results in castings which are remarkably free of (micro)porosity.
Unlike permanent mold, sand or investment casting, it is unusual to find microporosity in HIHP
castings. High integrity high pressure castings utilize hardened steel dies to withstand the high
metallostatic pressures (Fig. 1-3). This combination of metal tooling and high pressure (which
keeps the cast alloy in intimate contact with the die surface) promotes very high cooling rates in the
castings, which results in exceptionally fine micro-structures. The fineness of the microstructure
can be characterized by the parameter “secondary dendrite arm spacing” (SDAS), which is a
measure of the local solidification rate, and is observable under a microscope.
Because the cooling rates are so high, the secondary dendrite arm spacings associated with
the casting processes are often as much as an order of magnitude smaller than equivalent sand
or permanent cast components (see Table 1-2a). The combination of fine-scale microstructures

1-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

and lack of microporosity mean that HIHP castings typically exhibit superior mechanical
performance compared to castings produced by other processes. 1
High vacuum, squeeze and SSM casting equipment and tooling are comparable cost-wise to
other high pressure processes (slightly higher in the case of high vacuum die casting), but signifi-
cantly higher than most equipment used in sand and permanent mold casting. The productivity
and product capabilities (near net shape, wall thickness, etc.) of high vacuum, squeeze and SSM
casting, however, can more than offset less capital-intensive processes so that “annual pounds of
salable product per investment dollar” is very competitive, provided that annual volumes warrant
or utilize high productivity. Combined with the inherent near-net shape benefits (Fig. 1-4),
these attributes often make HIHP castings an unbeatable choice for many of today’s demanding
structural light metal applications. HIHP castings can be produced with tolerances which match
or, in some cases, exceed those of conventional high pressure die casting (see Sections 4 & 5). In
addition, close tolerance die cavity dimensions and the ability to use moveable cores allows detail
to be cast into the components that reduce machining requirements even further.
Before committing to producing a part with a HIHP process it is recommended that a
designer find a die caster who can perform the HIHP process desired. This has the additional
benefit of involving a die caster early in the process to provide design recommendations that can
improve the manufacturing process.

Fig. 1-1a Micrograph of solidification

shrinkage in an aluminum casting.

Fig. 1-1b Micrograph of entrapped gas

porosity in an aluminum die casting.

Fig. 1-1c Section through a semi-solid metal

cast master brake cylinder, showing the lack
of both gas and shrinkage porosity.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-3
 High Integrity High Pressure Casting Processes

Fig. 1-2 Externally, both castings would

look the same after the cavity is filled.
Semi-solid presents a calm, slow fill and
high pressure results in a fast and turbulent
fill with tighter dendritic spacing feeding
thinner casting sections.

Relation between Casting Pressure and Velocity of the metal at the Gate Fig. 1-3 Casting pressure used in the squeeze
100
casting and semi-solid metal casting process.
Die Casting
& High Vacuum Die Casting
Gate Velocity [m/s]

SC-Technology
10

SSM Casting

Medium Pressure DC
1
Gravity Die Casting
Low Pressure DC
Squeeze Casting
0.1
0.1 1 10 100 1000
Casting Pressure [bar]

Fig. 1-4 Examples of HIHP cast

components, showing the net shape
capability of the process.

Fig. 1-5a Horizontal injection process

used for squeeze casting.

1. Pouring 2. Shot unit tilts to injection

position during die clamping
3. Sleeve lifted by docking
cylinder and sets into the die
4. Plunger tip goes up to molten
metal into the die cavity
Fig. 1-5b Vertical injection process
used for squeeze casting.

1-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

1 High Vacuum Die Casting

1
Although vacuum (assisted) die casting has been used in the die casting industry for many
years, a new process generally called high vacuum die casting (or structural die casting) allows
the production of aluminum die castings that are being used in structural car body and other
safety-critical applications due to better strength, much higher elongation and excellent impact
and fatigue resistance. Figure 1 demonstrates the energy absorbing ability, showing a component
produced by two welded high vacuum die castings subsequent to a crash test. This ability to
absorb energy is quite remarkable for a die casting, and conventional die castings (even those
produced using vacuum assist) do not exhibit such behavior.
Fig. 1-6 Casting produced by high vacuum
die casting subsequent to a crash test(1),
demonstrating the ability to absorb energy
without cracking.

The high vacuum die casting process maintains the fast injection speed used by conventional
die casting, but powerful vacuum systems reduce the air pressure in the die cavity and shot sleeve
to typically less than 50 milli-bar (<1/20 of an atmosphere), so there is little gas remaining in the
cavity to become trapped in the castings. The advantages of high vacuum die casting include:
• In combination with the use of low-iron aluminum alloys provides excellent ductility and
toughness, which allows the castings to be used in structural, safety critical applications.
• The use of high vacuum minimizes the amount of entrapped gasses, providing the ability
to optimize strength and ductility through heat treatment.
• High vacuum die casting is capable of producing large, thin-walled (0.08-0.16 inches/2-4
mm) structural castings and such castings are being used to replace steel or aluminum
stampings in car body and chassis, as well in other applications.
Along with the use of a powerful vacuum system, there are a number of changes to the process
that are necessary to achieve this level of performance. The main aspects of high vacuum die
casting include:
• Use of low-iron aluminum die casting alloys to maximize strength and ductility
• Metal treatment and handling to optimize metal quality
• Special die, gating, overflow, vacuum channel, etc. designs
• Powerful vacuum systems, sealed dies and advanced vacuum controls to achieved desired
vacuum levels in the cavity
• Controlled thermal treatment of the castings to obtain strength-ductility combinations
Some of these are discussed below in more detail.

1.1 Low-Iron Die Casting Alloys (1)

There a number of aluminum alloys that have been specially designed for the high vacuum die
casting process, and the chemical compositions of some of the common alloys are listed in Table
3-2 (see Section 3 - Chemical, Mechanical, & Physical Properties of High Vacuum, Squeeze,
and Semi-Solid Die Castings). With a few exceptions, most of these alloys contain relatively
high levels of silicon (between 6.5 and 11.5%), and all contain low levels of iron (≤0.25%), which
helps provide high levels of ductility (elongation). Die soldering is minimized through the
addition of Mn at levels of 0.25-0.8% (and in some cases Sr).

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-5
 High Integrity High Pressure Casting Processes

1.2 Treatment and Handling to Optimize Metal Quality

As high vacuum die castings are normally used in structural applications, much greater care
needs to be taken to optimize the quality of the metal (compared to other die casting processes).
Therefore, the alloys must be cleaned (fluxed and filtered) and de-gassed using a rotary degassing
process. Rotary degassing involves the introduction of an inert gas below the level of the liquid
aluminum, and the rotary impeller produces a uniform distribution of small insert gas bubbles
throughout the liquid aluminum. Any dissolved gas (hydrogen), along with small impurity
inclusions (such as oxides), attach to the bubbles and rise to the surface of the melt, where they
are removed(2). The metal must at all times be treated with utmost care and all cascades avoided
(quiescent transfer, repeated filtering, continuous degassing in the holding/dosing furnace are
common elements).

1.3 Robust Die, Gating and Overflow Designs

The gating system used with high vacuum die casting is modified from conventional die casting.
High vacuum die casting castings are usually produced with a much larger number of gates (as
many as 20-50 gates), in contrast to the 3-5 gates commonly used with conventional die castings.
For example, a B-pillar high vacuum die casting produced for the Audi A2 has been reported
to use 46 gates. Overflows and vacuum gates are equally important to ensure proper evacuation
throughout the entire filling process without injecting the metal into the vacuum system.
Overflows are also used to maintain proper thermal balance in the die as the thin walled castings
introduce much less heat into the die than conventional (thick walled) die castings and die spray-
ing is absolutely minimized and only used for lubrication and not for controlling the thermal
balance of the die. Thermal balance of the die is controlled by a much more sophisticated system
of heating and cooling channels in the die.

1.4 Powerful vacuum systems

There are a number of proprietary systems used for high vacuum die casting, including the
High-Q-Cast process, Vacural and Alcoa Vacuum Die Casting (AVDC). Most elements of such
processes are commercially available individually (and can be retrofitted to existing machines)
or as a package. Each of these processes have in common the use of powerful vacuum systems
(one or two stage, with one or several channels) and advanced vacuum controls to quickly reduce
the pressure in the cavity and shot sleeve below 50 milli-bar at the beginning of the fast shot. In
addition, to minimize vacuum leaks, seals and special die designs are used on all die surfaces/die
components, making the dies much more complex than used for conventional die casting.

1.5 Controlled Thermal Treatments

Although the castings can be used in the as-cast condition, the significantly lower levels of
entrapped gases allow the castings to be heat treated without blistering. Components can be heat
treated after casting to maximize strength, ductility or toughness. The very high freezing rate of
thin walled high vacuum die castings allows for much shorter solution heat treatment times than
thick walled castings (e.g. produced by permanent mold or sand casting), but the thin walled
components can also much more easily distort during quenching and therefore require special
(precision air quench) processes and fixtures to avoid or minimize this problem – and they often
need to be straightened and brought back into tolerances after T6/7 heat treatments..
Both T5 and T6/7 heat treatments can be performed to optimize mechanical properties. T5 heat
treatments involve water quenching directly after the castings have been ejected from the casting
die, followed by a low temperature (150-250°C/300-482°F) aging treatment. T6 heat treating
involves heating the castings to a temperature close to their melting (solidus) temperature, followed
usually by a water quench and a low temperature age. Note that a streamlined T6 heat treatment
has been developed for use with the Aural type alloys, which has been named Auraltherm.
This is now also commonly being used in combination with most other (previously described)
structural alloys. In contrast to traditional solution heat treatment temperatures of around 500°C

1-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

(930°F) combined with water quenching, the Auraltherm process involves a “partial solution heat
treatment” at a slightly lower temperature followed by rapid air cooling. Because high vacuum
die castings are typically thin walled, air cooling provides a sufficiently high cooling rate, while
1
minimizing distortion that can occur during water quenching of thin-walled components. Fol-
lowing the quench, the Auraltherm treatment involves a lower temperature aging treatment. For
highest ductility this aging is performed at higher temperatures and/or longer time to “over-age”
and hence long term stabilize the castings (T7 process).

2 Squeeze Casting

Squeeze casting is a term commonly used today to refer to any process in which a liquid alloy is
cast without turbulence and gas entrapment and subsequently held at high pressure throughout
the solidification cycle to yield high quality heat treatable components. Squeeze casting
originally was developed as a liquid forging process, in which liquid metal was poured into the
lower half of a horizontally-parted die set and subsequently closed die forged (this process is
now termed “direct squeeze casting”). In contrast, “indirect squeeze casting” describes a process
where the liquid alloy is injected into a cavity via large in-gates, which allows the feeding of
solidification shrinkage throughout the freezing process.
Today, the term squeeze casting almost universally relates to the “indirect” process utilizing a
runner and gating system. Squeeze castings are made on machines and in steel tooling that are,
in many respects, like those employed in conventional die casting. Machines and dies are very
robust and capable of containing very high molten metal pressures without deflecting or losing
dimensional control.
Squeeze casting machines and tools are designed to introduce clean molten metal into the tool
in a precise, repeatable, controlled manner, filling the cavity quickly but without turbulence.
In commercial practice today, there are systems employing either vertical or horizon- tal injec-
tion systems, with the parting line of the die orientated either horizontally or vertically. Figures
1-5a & 1-5b illustrate two of the many process variations in use today around the world.
Squeeze castings can be made from the full range of heat treatable (and non-heat treatable too,
if desired) alloys utilized in the permanent mold processes. Only the “hot- short” 2XX, 5XX
and 7XX alloys, sometimes used in sand and plaster-mold casting, are not suitable for squeeze
casting. Squeeze castings are not limited to the higher silicon (higher fluidity) alloys needed
for conventional high pressure die casting. Squeeze castings also do not require the high iron
impurity level needed in die casting to prevent “soldering” when molten aluminum is “sprayed”
into the die – in fact, high iron concentrations are generally undesirable as they will reduce
mechanical properties.
Casting cycles are generally somewhat slower than for conventional die casting. Machine
utilization, however, is comparable to that of conventional die casting.
Because metal velocities entering the cavity are considerably slower than die casting, dispos-
able internal cores are more readily applied in squeeze casting, although only cores and core
washes that can withstand great metal pressures are suitable.

3 Semi-Solid Metal Casting

Semi-solid casting differs from squeeze casting as, instead of using fully liquid alloys, it uses
a “novel” semi-solid slurry as the feed material. However, similar to squeeze casting, most
semi-solid processes use high pressure die casting machines to inject the semi-solid slurry into
re-usable, hardened steel dies.
The feed material used for semi-solid processing must have a special “globular” microstructure,
such as that shown in Figure 1-7a. The primary aluminum particles (the white-colored phase)
must be spherical or globular in shape, and surrounded by eutectic (the dark phase). For compari-
son, Figure 1-7b shows the dendritic microstructure found in conventional castings. When the

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-7
 High Integrity High Pressure Casting Processes

globular structure shown in Figure 1-7a is within the semi-solid temperature range, the primary
aluminum particles will comprise the solid fraction and the eutectic will be liquid. So at the
semi-solid casting temperature, the microstructure will consist of a slurry of small globular solid
particles dispersed in a liquid. When this mixture is injected into the die, the semi-solid slurry
behaves as a viscous liquid. The principle advantage of semi-solid casting is that this high viscos-
ity slurry allows the use of much faster injection velocities before the onset of turbulence. This
allows the semi-solid process to produce extremely high quality castings while filling remarkably
thin-walled components at high production rates.
a) b)
Fig. 1-7 Aluminum alloy 357 micro-
structures

a) Globular microstructure required

for semi-solid processing
b) Conventional cast dendritic
microstructure.

Commercial SSM casters are utilizing both horizontal and vertical injection systems,
although horizontal injection is more common. SSM casters often use horizontal die casting
machines fitted with real-time controlled injection units, which provide the control necessary
to avoid turbulence during injection of the semi-solid slurry into the cavity. As with squeeze
casting, the metal is typically fed into the cavity through relatively massive runners and gates,
which provide paths for the feeding of solidification shrinkage.
SSM castings can be produced from a range of aluminum and magnesium alloys as described
below. In addition, cycle rates for SSM castings tend to be faster than both die casting and
squeeze casting, as the semi-solid metal can be injected into the cavity at relatively high speeds,
and as solidification times are reduced due to the feed material already being 50% solidified. It
should be noted that die life for SSM castings should be better than for die casting and signifi-
cantly better than squeeze casting, as SSM castings are produced at lower casting temperatures.
As noted earlier, there are currently three semi-solid processes in use around the world
(thixocasting, rheocasting and thixomolding). These will be described in more detail the follow-
ing sections.

3.1 Thixocasting
The thixocasting process, which is shown schematically in Figure 1-8, can be considered to
consist of three separate stages - the production of a billet feedstock having the special globular
microstructure, the re-heating of the billets to the semi-solid casting temperature and the
casting of the components.
The feedstock for the thixocasting process is typically produced on a DC casting system equipped
Fig. 1-8 Schematic representation of
Dendritic DC/EM the thixocasting process.
structure stirring

Cut into
slugs SSM cast
structure

Slug Heating
EM stirred
structure Semi-Solid
casting

1-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

with electromagnetic stirrers. As the cylindrically-shaped bars are being cast, the liquid metal is
vigorously stirred to prevent the formation of dendrites, instead generating the globular, semi-solid
structure. Generally the bars are produced at primary aluminum plants and shipped to the semi-solid
1
caster. Slugs are then cut from the bars, and reheated to the semi-solid casting temperature using
induction heating. Figure 1-9 shows the consistency of a re-heated slug, which usually has a solid
fraction of 40- 50% (50-60% liquid). For alloy 357 this corresponds to a temperature of about 580°C
(1076°F). At this temperature, essentially all the eutectic portion of the alloy is liquid.

Fig. 1-9 Consistency of alloy A357 slug

at the semi-solid metal temperature.

Once at the semi-solid casting temperature, the slugs are transferred to the shot sleeve of a
horizontal die casting machine and injected into the die. Due to the high viscosity of the semi-
solid alloys, a greater force is needed to fill the cavity as compared to die casting. Consequently,
semi-solid machines generally have a larger capacity shot end than a conventional die casting
machine of the same locking force.
Although thixocast parts can be produced from a range of alloys, most of the commercial
castings are being produced from heat-treatable aluminum foundry alloys such as A356, 357,
366, A390 and a high strength version of 319.
One of the advantages of thixocasting is the product quality and consistency that results
from using pre-cast billets manufactured using the same techniques to control metal quality
as are employed to make forging or rolling stock. Thixocasting billets have billet-to-billet and
lot-to-lot chemistry, cleanliness and microstructural repeatability comparable to forging and
rolling stock, and far more consistent than is achievable when pouring castings from the liquid
in single doses. Thus semi-solid components produced by the billet approach tend to have very
consistent properties. As noted earlier, the disadvantage associated with thixocasting is its higher
manufacturing cost. This arises both from the premium attached to the price of the feedstock, as
well as the inability to easily recycle biscuits and runners. Billet is also available from only a few
global sources and in a limited number of alloys.

3.2 Rheocasting
Instead of re-heating a pre-cast slug, rheocasting generates the special semi-solid microstructure
adjacent to the die casting machine directly from the liquid. A schematic drawing of the
rheocasting process is shown in Figure 1-10. The metal is cooled into the semi-solid temperature
range while simultaneously generating the semi-solid structure. Once the metal has been cooled
to the correct semi-solid temperature, the slurry is transferred to the shot sleeve of a die casting
machine, and injected into the die, again using controlled filling to minimize turbulence.
Rheocasting first entered commercial production in the late 1990’s. Today there are a number
of different rheocasting processes either in commercial production or under development around
the world, many developments of which have been encouraged by the higher cost of thixocasting.
These rheocasting or slurry-ready processes generally use one of three different techniques to
generate the globular microstructure, either stirring, dendrite fragmentation or pouring from a
low superheat to generate numerous solidification nuclei.
The major advantage of rheocasting over thixocasting is that, as the semi-solid feed material
NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-9
 High Integrity High Pressure Casting Processes

is produced at the casting machine by cooling from the liquid, a special feed material is not
required. Instead conventional ingot material can be used, eliminating the surcharge associated
with the thixoforming billet. Another advantage is that biscuits and runners can now be recycled
directly into the casting stream, again reducing cost (see Figure 1-10). However, especially when
compared to thixocasting, much greater care must be taken with metal cleanliness when produc-
ing parts using rheocasting.
It is worth noting that not all rheocasters are focusing on the production of structural,
safety-critical components. Rheocasting provides much greater flexibility for casting lower solid
fraction slurries, and some rheocasters are producing castings using solid fractions as low as
15%. As these lower solid fraction slurries will be less viscous, turbulence during die filling can
become more of an issue. Consequently, these low solid fraction rheocasting processes are gener-
ally being used to produce die casting-like parts having reduced porosity levels (often eliminating
the need for impregnation).
Alloys used for rheocasting include not only the foundry-type alloys (A356, 357, 366, A390,
high strength 319), but also alloys used more typically for die casting such as 380 and 383.

3.3 Thixomolding
Note: Thixomolding is a proprietary process licensed by Thixomat Inc.

Thixomolding, a process that combines many of the aspects of die casting, semi-solid casting and
plastic injection molding, is a semi-solid process for the production of components exclusively
from magnesium alloys. It uses a specially designed machine, closer in design to a plastic
injection molder than a die casting machine.
The thixomolding process is shown schematically in Figure 1-11. Special magnesium alloy
pellets or chips are used as the feed material for the process. Room temperature chips are fed
into the back end of a heated steel barrel using a volumetric feeder. The barrel is maintained
under an argon atmosphere, to reduce oxidation of the magnesium chips. The barrel is heated in
several zones, typically by radiant heaters located on the outside of the barrel. Inside the barrel,
rotation of the screw moves the magnesium chips forward as they are heated into the semi-solid
temperature range.
Once semi-solid, the screw rotation provides the necessary shearing force to break up the

Fig. 1-11 Schematic drawing of

thixomolding process.

dendrites and produce the globular particles required for semi-solid casting. A nominal slurry
injection temperature for magnesium alloy AZ91D is 580°C (1076°F), which corresponds to a
solid fraction of about 30%. Once the semi-solid slurry reaches the front of the heating zone, it is
forced through a non-return valve and into an accumulation zone. When the appropriate amount
of slurry is collected in the accumulation zone, the screw moves forward to force the semi-solid
slurry into the pre-heated steel die to produce a near-net shape part. Pressure is maintained
during solidification to reduce porosity. Once the component has solidified, the screw retracts
and the process repeated.
As the semi-solid slurry is fully contained within the barrel of the thixomolding machine,
this also allows thixomolders to make parts over a wide range of solid fractions. Thixomolded
components are produced with solid fractions as high as 40-50%, or as low as 5%. Typically the
thinner walled components will be produced using lower solid fractions to optimize flow length,

1-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

but obviously at such a low solid fraction the slurry will be more fluid, potentially generating
turbulence during die filling. The production of structural components will utilize higher solid
fractions (30% or greater) to minimize turbulence and so entrapped gasses.
1
Thixomolding cannot be used for aluminum alloys due to the semi-solid slurry being contained
within a steel barrel and being stirred by a steel augur. Similar to issues preventing the hot
chamber die casting of aluminum, the use of semi-solid aluminum in the thixomolding machine
would dissolve the steel augur and barrel.
The first thixomolding machine was built in 1991 and thixomolding entered commercial
production shortly afterwards. Similar to die casting machines, thixomolding machines are sized
based on the clamping force applied to the platens. Thixomolding machines typically range in
size from 75 tons to 1600 tons or so.
The main advantages of the thixomolding process are lower porosity, longer mold life (due to
the lower casting temperature), more rapid start-up, changeover and shut down of the process,
and reduced melt loss. Another advantage is that thixomolding avoids the foundry environment,
as the semi-solid magnesium is completely contained within the thixomolding machine. How-
ever, cycle rates for a thixomolding machine tend to be slower than for conventional hot chamber
die casting. In addition, the chipping process used to produce the feed material for thixomolding
adds cost over conventional ingot material.
Thixomolders typically use the same magnesium foundry alloys as hot chamber die casters,
such as AZ91, AM50 and AM60.
Mechanical properties of these alloys after high vacuum die casting are listed in Tables 2 - 4.

Summary
Table 1-1 summarizes many of the processing parameters used with squeeze casting and the
three semi-solid casting processes, and compares them to conventional high pressure die casting.

Table 1-1 Comparison of process parameters for thixocasting, rheocasting, thixomolding, and
conventional high pressure die castings.
High Vacuum Squeeze
Parameter Die Casting Thixocasting Rheocasting Thixomolding
Die Casting Casting
Feed Material Liquid Liquid Liquid Semi-solid Semi-solid Semi-solid
Gate Size Thin Thin Thick Thick Thin or thick Thin
Injection
Fast Fast Very Slow Slow Slow to fast Fast
speed
Intensification Medium to
Normal Normal High High Medium to high
pressure high
<400
Vacuum <50 millibar
millibar
Low to Low to
Porosity level High Low to very low Very low Low
very low very low

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-11
 High Integrity High Pressure Casting Processes

4 Comparisons of High Vacuum, Squeeze, SSM and Other Casting Processes

The following tables show comparisons of a number of processing characteristics for High Vacuum,
Squeeze, SSM and other casting processes. The single digit entries (1,2,3,4 or 5) in the tables are
intended to be a qualitative indicator with 1 being most favorable and 5 being least favorable.

Table 1-2a: Product Characteristics – Strength & Integrity Factors

Mass Produciton Solidificaiton Rate Shrinkage Pressure Solution Heat Alloy Range MMC Surface Available Available
Microporosity Weldability
Process (SDAS) Feeding Tightness Treatable Applicable Applicable Integrity Strength Ductility

DIE CAST
Conventional 5-25 5 4 4 No 4 5 1 5 5 5
Controlled Shot 5-40 4 3 3 Limited 4 3 1 4 4 4
Vacuum 5-25 2 3 3 Limited 4 3 1 4 3 4
High Vacuum 5-25 1 2 1 Yes 3 3 1 1 1 1

SQUEEZE CAST
Direct 25-78 1 1 1 Yes 3 1 3 1 1 1
Indirect 5-25 1 1 1 Yes 3 2 1 1 1 1

SEMI-SOLID CASTING
Thixocasting 10-40 1 1 1 Yes 3 1 1 1 1 1
Rheocasting 10-40 1-2 1-3 1-3 Yes 2 1 1 1-3 1 1
Thixomolding 5-15 2-5 3-4 1-4 Yes 4 1 1 3 4 2

SAND PROCESS
Green 40-100 5 4 4 Yes 1 3 5 2 3 3
Dry 30-80 4 4 4 Yes 1 3 4 2 3 3
Cosworth 25-60 3 3 3 Yes 1 5 4 2 3 3
Lost Foam 50-150 5 4 4 Yes 4 5 5 2 5 5

PERMANENT MOLD
Gravity, Static 20-60 3 3 3 Yes 2 3 3 2 3 2
Gravity, Tilt 20-60 3 3 3 Yes 2 4 3 2 3 2
Low Pressure 20-60 2 2 2 Yes 3 5 3 2 2 2
Counterpressure 20-60 2 2 2 Yes 3 5 2 2 2 2
Cast Forged 15-40 2 2 2 Yes 4 3 2 2 2 2
High Vacuum 5-25 1 2 1 Yes 3 3 1 1 1 1

FORGING N/A 1 N/A 1 Yes 5 3 3 1 1 1

1-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
 High Integrity High Pressure Casting Processes

Table 1-2b: Product Characteristics – Dimensional & Complexity Factors

Surface
1
Net Shape Capabilities Dimensional Tolerance
Finsih
Mass Produciton Dimensional Machining Minimum Across
Part Complexity Linear Draft Thickness Flatness Smoothness
Process Repeatability Allowance Walls Parting

DIE CAST
Conventional 1 1 1 1 1 2 2 2 2 1
Controlled Shot 2 1 2 1 1 2 2 2 2 1
Vacuum 1 1 1 1 1 2 2 2 2 1
High Vacuum 1 1 1 1 1 2 2 1 1 1

SQUEEZE CAST
Direct 4 2 5 4 3 5 4 5 1 2
Indirect 2 1 3 1 1 2 2 3 2 1

SEMI-SOLID CASTING
Thixocasting 2 1 1 1 1 1 1 2 2 1
Rheocasting 2 1 1 1 1 1 1 2 2 1
Thixomolding 2 1 1 1 1 1 1 1 2 1

SAND PROCESS
Green 2 5 5 5 5 3 5 4 4 5
Dry 2 3 3 4
Cosworth 2 3 3 4 4 3 4 3 3 4
Lost Foam 1 2 3 2 3 1 1 1 5 5

PERMANENT MOLD
Gravity, Static 3 3 4 3 3 4 4 3 3 3
Gravity, Tilt 3 3 4 3 3 4 4 3 3 3
Low Pressure 3 3 4 3 2 4 3 3 3 3
Counterpressure 3 3 4 3 2 4 3 3 3 3
Cast Forged 5 2 5 4 2 5 4 4 2 2

FORGING 5 2 5 5 2 5 5 5 1 2

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-13
 High Integrity High Pressure Casting Processes

Table 1-2c: Product Characteristics – Machine & Tooling Factors

Machine Combined Tooling

Mass Produciton Productivity Utilization Internal Cast-In Development Change Multi-

Materials Life Cost
Process (Cycle Time) (Up Time) Coring Inserts Time Flexibility Cavity

DIE CAST
Conventional 2 5 5 1 Tool Steel 3 3 4 5 3
Controlled Shot 2 4 3 2 Tool Steel 3 2 5 5 3
Vacuum 2 5 5 1 Tool Steel 3 3 5 5 3
High Vacuum 1 4 4 1 Tool Steel 2 4 5 5 3

SQUEEZE CAST
Direct 5 4 5 4 Tool Steel 2 4 4 5 5
Indirect 3 3 3 1 Tool Steel 5 4 5 5 3

SEMI-SOLID CASTING
Thixocasting 1 1 3 1 Tool Steel 5 1 4 5 3
Rheocasting 1 2 3 1 Tool Steel 5 1 4 5 3
Thixomolding 2 2 3 1 Tool Steel 5 1 4 5 3

SAND PROCESS
Green 1 1 1 5 Plastic-Steel 1 1 1 1 1
Dry 4 2 1 3 Iron-Steel 2 3 3 2 4
Cosworth 4 2 1 3 Iron-Steel 2 2 2 2 4
Lost Foam 3 2 1 5 Aluminum 4 1 2 2 3

PERMANENT MOLD
Gravity, Static 4 2 2 4 Iron-Steel 3 4 2 3 3
Gravity, Tilt 4 2 3 4 Iron-Steel 3 4 2 3 4
Low Pressure 5 3 2 3 Iron-Steel 2 4 3 4 3
Counterpressure 5 3 2 3 Tool Steel 3 3 3 4 4
Cast Forged 5 3 5 5 Tool Steel 2 4 4 4 5

FORGING 1 4 5 5 Tool Steel 2 2 4 5 5

1-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
High Integrity High Pressure Casting Processes

Table 1-2d: Product Characteristics – Casting Factors

Mass Produciton Directed °F/Sec Sec Cavity/ KSI °F Die/Mold ° F Pouring
1
Metal Flow
Process Solidification Solidifications Fill Time Solidifications Temperature Temperature

DIE CAST
Conventional 5 4 1 0.04-0.1 10-15 300-450 1175-1250
Controlled Shot 4 4 2 0.05-0.2 6-12 400-600 1225-1300
Vacuum 4 4 1 0.04-0.1 4-8 300-450 1175-1250
High Vacuum 2 2 1 0.03-0.1 4-8 400-600 1175-113

SQUEEZE CAST
Direct 2 4 3 5-25 15-40 450-600 1300-1350
Indirect 1 1 1 0.5-2 10-20 450-600 1275-1400

SEMI-SOLID CASTING
Thixocasting 1 1 1 0.1-0.5 10-20 300-600 <1100
Rheocasting 1 1 1 0.05-0.5 10-20 300-600 <1150
Thixomolding 1 1 1 0.04-0.2 5-20 200-600 <1150

SAND PROCESS
Green 3 4 4 5-25 Atmos. Ambient 1300-1400
Dry 3 3 4 5-25 Atmos. Ambient 1300-1350
Cosworth 1 3 3 5-25 Atmos. Ambient 1300-1350
Lost Foam 2 5 5 5-25 Atmos.

PERMANENT MOLD
Gravity, Static 3 3 3 5-25 Atmos. 600-800 1300-1500
Gravity, Tilt 2 2 3 10-30 Atmos. 600-800 1300-1450
Low Pressure 1 2 3 10-60 Atmos. 600-800 1275-1350
Counterpressure 1 2 3 10-60 0.2-1 600-800 1275-1350
Cast Forged 2 4 2 5-25 Atmos. 400-600 1250-1300

FORGING N/A N/A N/A N/A N/A 300-600 N/A

NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021 1-15
 High Integrity High Pressure Casting Processes

Table 1-2e: Economics – Process & Product Cost Factors

Process Product

Mass Produciton Raw Component Near-Net

Overall Equipment Tooling Casting Processing
Process Material Weight Shape

DIE CAST
Conventional 1 4 4 1 1 1 2 1
Controlled Shot 3 4 5 3 1 2 2 1
Vacuum 2 4 5 2 1 2 2 1
High Vacuum 3 4 5 2 1 3 1 1

SQUEEZE CAST
Direct 3 4 4 3 3 2 1 3
Indirect 3 5 5 2 2 2 1 2

SEMI-SOLID CASTING
Thixocasting 4 5 4 3 1 5 1 1
Rheocasting 2 5 4 2 1 2-3 1 1
Thixomolding 2 5 4 2 1 4 1 1

SAND PROCESS
Green 1 2 1 1 5 1 5 4
Dry 3 3 2 2 4 2 5 3
Cosworth 2 3 2 2 4 3 4 3
Lost Foam 1 3 2 1 — — — —

PRECISION PROCESS
Investment 3 3 2 3 2 4 2 1
Plaster 3 2 1 3 4 4 2 1

PERMANENT MOLD
Gravity, Static 2 1 3 3 4 1 4 3
Gravity, Tilt 2 2 3 3 3 2 4 3
Low Pressure 2 1 3 3 2 2 3 3
Counterpressure 2 2 4 3 2 2 3 3
Cast Forged 4 2 4 3 1 3 3 4

FORGING 4 5 4 4 4 4 1 5

1-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 1 / 2021
 2
Heat Treatment & Temper Designations section
for High Vacuum, Squeeze & SSM Casting
Section Contents Page
1 Heat Treatment 2-2
1.1 Solution Heat Treatment 2-2
1.2 Quenching 2-2
1.3 Precipitation Heat Treatment 2-2 2
2 Heat Treatment Issues and Controls 2-3
2.1 Solution Treatment Temperature 2-3
2.1.1 Overheating 2-3
2.1.2 Underheating 2-3
2.2 Excessive Heating Rate 2-3
2.3 Casting Blisters 2-3
2.4 Solution Treatment Time 2-3
2.5 Quenching 2-4
3 Temper Designations 2-4
3.1 Major Subdivision of T Temper (T4, T5, T6, T7) 2-4

NADCA Standards for High Integrity and Structural Die Casting Process / Section 2 / 2021 2-1
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
1 Heat Treatment
Examination of the heat treatment of nonferrous alloys reveals a wide variety of processes are
employed. The process of precipitation and the hardening that accompanies it are especially
important in aluminum alloys, and also in some magnesium and copper alloys.

1.1 Solution Heat Treatment

A prerequisite to precipitation hardening is the ability to heat the alloy to a temperature range
wherein the hardening elements are dissolved. This is possible because, for many alloys, a solid
solution can dissolve a greater concentration of hardening elements at an elevated temperature
than at room temperature. This solid solution structure, containing a higher concentration of
hardening elements, is then retained at ambient temperatures by cooling rapidly (for example,
water quenching) to prevent the precipitates from forming. At room temperature, this solid solu-
tion structure is supersaturated with respect to the hardening elements, and hence is unstable.

1.2 Quenching
This is the second important step in the sequence of heat treating operations. The objective is to
preserve the solid solution formed at the solution heat-treating temperature. As a broad gener-
alization, the highest strengths available and the best combinations of strength and toughness
are those associated with rapid quenching rates, as achieved by quenching into agitated water.
Resistance to corrosion and stress corrosion cracking are other characteristics that are generally
improved by the fastest quenching rates. For maximum dimensional stability, some castings
are fan cooled or even cooled in still air. In such instances, precipitation-hardening response is
limited, resulting in lower strength and hardness.

1.3 Precipitation Heat Treatment

After solution heat treatment and quenching, precipitates can then form. In fact, in some alloys,
precipitation can occur spontaneously at room temperature. However, for most alloys, this
process is both speeded up and controlled through a controlled elevated temperature “aging”
process. This process occurs by raising the temperature of the casting to promote the chemical
diffusion process, which allows the supersaturated hardening elements to concentrate and “pre-
cipitate” out of the supersaturated solid solution. It is this formation of fine precipitates evenly
distributed throughout the matrix that provides the higher strength. Choice of time-temperature
cycles for precipitation heat treatment should receive careful consideration. Larger particles of
precipitate result from longer times and higher temperatures; however, the larger particles must
of necessity be fewer in number with greater distances between them. The objective is to select
the cycle that produces optimum precipitate size and distribution pattern. Unfortunately, the
cycle required to maximize one property, such as yield strength, is usually different from that
required to maximize others, such as elongation or corrosion resistance. Consequently, the cycles
used commercially represent compromises that provide the optimum combinations of properties.
Parts may be “under-aged” or “over-aged” to achieve specific combinations of strength, ductility,
corrosion resistance, and stability. Generally, the hardness and strength will increase and the
ductility will decrease at more severe aging parameters. However, with longer aging times, the

Fig. 2-1 Effect of age hardening temperature

for alloy AlSi7Mg(A356).

2-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 2 / 2021
Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
strength starts to drop and the elongation increases. (Fig. 2-1) This is termed over-aging. The
over-aging process is accelerated at higher temperatures.

2 Heat Treatment: Issues & Controls

It is advised that an OEM and die caster discuss heat treatment requirements during the design
stage to optimize the casting and process. There are some common issues with heat treatment
2
that can be avoided with proper design and controls.

2.1 Solution Treatment Temperature

2.1.1 Overheating
Nominal commercial solution heat-treating temperature is determined by the composition limits
of the alloy, with an allowance for unintentional excessive temperature variations. Care must be
exercised to avoid exceeding the solidus temperature. If appreciable eutectic melting occurs as
a result of overheating, properties such as tensile strength, ductility, and fracture toughness will
be degraded. Materials that exhibit microstructural evidence of incipient melting/overheating
are generally considered unacceptable. The lower limit for the solution heat treatment is based on
maximizing the amount of hardening elements dissolved in the solid solution.

2.1.2 Underheating
When the temperature attained by the parts is appreciably below the normal range, the amount
of hardening elements dissolved in the solid solution will be reduced and the strength, after
aging, will be somewhat lower than expected.

2.2 Excessive Heating Rate

When high heating rates are employed, the phenomenon of non-equilibrium melting must be
considered. This phenomenon occurs when certain phases or compounds are slow to dissolve
in the solid solution. When the heating rate is rapid, much of these phases will melt before the
diffusion process has time to disperse the compounds into the solution. If this occurs, and the
material is quenched before the liquid has had time to equilibrate, it will solidify and form fine
eutectic rosettes (incipient melting). Examination of the alloy microstructure should be included
as part of the certification process when faster heating rates are used.

2.3 Casting Blisters

High integrity-high pressure castings, produced by properly run high vacuum, squeeze and SSM
casting processes, contain very low levels of porosity. However, selection of plunger and die lubricants
for these processes is a critical issue. Incorrect selection and application of plunger and die lubricants
may result in residual material in the part that when exposed to the temperatures in solution heat
treatment, will break down and form blisters in the heat treated part, especially at the cast surface.

2.4 Solution Treatment Time

This is the time at temperature required to dissolve a satisfactory amount of the hardening phases
and to achieve good homogeneity within the solid solution. Solution treatment serves two functions
in Al-Si alloys, 1) solution of the precipitates and 2) spheroidization of the Si phase, which increases
ductility. The time required for spheroidization may be somewhat longer than the time required for
solutionizing. Both times are a function of the morphology of the microstructure before heat treat-
ment, and the thickness of the material section. Soak time is not considered to have begun until all
the instrumentation on the furnace and the load has stabilized at the desired temperature.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 2 / 2021 2-3
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
2.5 Quenching
Quench delay times, which are defined as starting when the furnace door begins to open until
the load is fully immersed in the quenchant are critical to the resulting mechanical propertiess.
The shorter the delay the better the results. Addtionally, residual stresses which can cause crack-
ing or lead to warpage in subsequent machining operations can be generated by non-uniform
quenching of thick and thin sections. This tendency can be reduced through special quenchants,
such as inversely-soluble polymers that prevent nucleation boiling on casting surfaces.

3 Temper Designations

The temper designations used in the United States for heat-treatable aluminum alloys are part of
the system that has been adopted by the American National Standard Institute (ANSI H35.1).
Used for all wrought and cast product forms except ingot, the system is based on the sequences
of mechanical or thermal treatments, or both, used to produce the various tempers. For the
purposes of this document, only the basic temper designations for cast products will be defined.

F, as-cast — cooled from the cast mold with no subsequent heat treatment.

O, annealed — medium-temperature thermal treatment intended to soften the casting and relieve
stresses; provides lowest residual stresses.

3.1 Major Subdivisions of “T” temper

In T-type designation, the T is always followed by a number; each number denotes a specific
sequence of basic treatments as described below.

T4, solution heat treated — thermal treatment just below the solidus temperature intended to
bring soluble phases into solid solutions; for a short time after solution heat treating, it provides
the “softest” condition, so it is sometimes suitable for machining or forming before aging to
full T6 or T7 temper. T4 is a reasonably stable and suitable temper in certain Al-Cu (2XX)
or Al-Zn/Mg (7XX) alloys, but not stable and not a final temper for the more common high
vacuum, squeeze and SSM Al-Si/Mg (3XX) alloys.

T5, artificially aged only — low temperature thermal treatment generally intended to strengthen
and harden the cast- ing; may also improve machinability; also relieves stresses and stabilizes for
service at el- evated temperatures. In most cases it is necessary to quench the casting immedi-
ately upon ejection.

T6, solution heat treated, quenched and artificially aged — generally produces the highest strength
and hardness, combined with reasonable ductility.

T7, solution heat treated, quenched and over-aged — provides the highest strength/hardness &
ductility combination with stress relief and stability for service at elevated temperatures. A
modified T7 heat treatment (Auraltherm or similar process) can be used with high vacuum die
castings. The Auraltherm process involves a “partial solution heat treatment” at a slightly lower
temperature followed by rapid air cooling. A normal aging treatment is used after quenching.
The process can be tweaked to meet the customer’s needs.

2-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 2 / 2021
 3
Chemical, Mechanical & Physical Properties of section
High Vacuum, Squeeze, and Semi-Solid Die Castings
Section Contents Page
1 Introduction 3-3
1.1 High Vacuum Die Casting 3-3
1.2 Squeeze Casting 3-3
1.3 Semi-Solid Casting 3-4
2 Aluminum Alloys 3-4
2.1 Cross Referencing of Aluminum Alloy Designations 3-4
2.2 High Vacuum Die Casting 3-4
2.2.1 Chemical Composition for High Vacuum Die Casting 3-4
2.2.2 Machanical Properties for High Vacuum Die Casting - F - Temper
2.2.3 Machanical Properties for High Vacuum Die Casting - T5 - Temper
3-5
3-5
3
2.2.4 Machanical Properties for High Vacuum Die Casting - T6/T7 Temper 3-5
2.3 Squeeze Casting 3-6
2.3.1 Chemical Composition for Squeeze and Semi-Solid Castings 3-6
2.3.2 Mechanical Properties for Squeeze Castings - F- Temper 3-7
2.3.3 Mechanical Properties for Squeeze Castings - T6 - Temper 3-7
2.4 Semi-Solid Casting 3-8
2.4.1 Processing Information for Thixocasting & Rheocasting - T5 temper 3-8
2.4.2 Processing Information for Thixocasting & Rheocasting - T6 Temper 3-8
2.4.3 Mechanical Properties of Thixocast Aluminum Alloys Heat 3-9
Treated to the T5 temper (Alloys 355, A567, & 357)
2.4.4 Mechanical Properties of Thixocast Aluminum Alloys Heat 3-9
Treated to the T6 temper (Alloys 319S, A356, 357, & A390)
2.4.5 Mechanical Properties of Rheocast Aluminum Alloys in the 3-10
F-temper (Alloys 319 & A356)
2.4.6 Mechanical Properties of Rheocast Aluminum Alloys Heat 3-10
Treated to the T5 temper (Alloys A356)
2.4.7 Mechanical Properties of Rheocast Aluminum Alloys Heat 3-10
Treated to the T6 temper (Alloys 319, A356, and 357)
2.5 Physical Properties of Aluminum Alloys Commonly Used for 3-11
Squeeze Casting & Semi-Solid Castings
3 Magnesium Alloys 3-11
3.1 Cross Referencing of Magnesium Alloy Designations 3-11
3.2 Chemical Composition of Magnesium Alloys for Thixomolding 3-12
3.3 Processing Information for Thixomolded Magnesium Components 3-12
3.4 Mechanical Properties of Thixomolded Magnesium Components 3-13
(Alloys AZ91D, AM-50, & AM-60)
3.5 Physical Properties of Magnesium Thixomolded Components 3-13
4 Property Comparison Chart 3-14

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-1
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings

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3-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings

1 Introduction
Alloys selected for high vacuum, squeeze and semi-solid metal (SSM) die castings are typically
chosen for specific mechanical or physical property requirements. However, castability issues
such as mold-ability, tool life, and hot tearing resistance must also be considered. It should be
noted that the property data for squeeze and semi-solid castings listed in this specification have
not been scrutinized by the manufacturing and user industries to the same degree as other types
of castings. Therefore, the data provided in this manual should be considered preliminary. The
data for high vacuum die casting alloy properties is taken from alloy producer and user publica-
tions. The data supplied in this manual have been collected from various sources to provide
typical values for the various alloys and HIHP casting processes.
Because of normal processing parameters, especially solidified under high pressure and/or in
absence of air, high vacuum, squeeze, and SSM die casting typically contains significantly less
3
micro porosity (both hydrogen and microshrinkage types) than is normally observed in perma-
nent mold. This results in somewhat higher properties and especially higher fatigue resistance.
Higher strengths and elongation are needed to create die castings that can be used in crash
worthiness applications. Improved properties also make it easier to join die castings to other
components (ie. higher elongation reduces cracking when riveting).

1.1 High Vacuum Die Casting

The steel welded assemblies that many of these castings replace, are significantly heavier. The
high vacuum levels are associated with the requirements to heat treat the castings to optimize
the properties achievable as production solutions.
In the high vacuum casting processes, the properties sought after are:
• High ultimate strength
• High elongation consistent with many body-in-white components
• Attachment complexity embedded in the design
Most commonly used high vacuum die casting alloys can be categorized within 2 main alloy
families, the typical 3xx series (Al-Si-Mg) alloys and the Al-Mg-Si type alloys. They all have
in common that the typically high levels of Fe (to beat die soldering) of traditional die casting
alloys is reduced to below 0.25% and replaced by Mn and in some cases also a small addition
of Sr. Successful tests have also been done with 7xx series alloys (Al-Zn-Mg type) alloys which
offer very attractive property packages. Die life strongly depends on the alloy composition as
well as process parameters. The Al-Si-Mg type alloys offer the easiest processability and part
design freedom (large, intricate, complex, thin walled) and are therefore the most commonly
used ones. They are either used in F or T5 temper or in T6/7 temper for highest elongation and
crash performance.

1.2 Squeeze Casting

For squeeze castings, two main casting characteristics are sought and they are similar to typical
requirements for permanent mold castings:
• Good fluidity or mold filling ability
• Resistance to hot tearing and hot cracking.
Alloys most generally used in squeeze casting commercial applications include A356, 357, 380
and A390. These alloys all contain sufficient silicon and other elements to have good fluidity
and resistance to hot tearing. Aluminum alloys that are less suitable for squeeze casting are the
casting alloys in the 2xx, 5xx & 7xx series, which are much more sensitive to hot tearing and
generally have poor mold filling ability.

1.3 Semi-Solid Casting

In semi-solid casting (SSM), resistance to hot tearing is also desirable, but the concept of fluidity
is less important due to the unique way the materials are processed.
NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-3
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
The most common aluminum alloys produced by semi-solid casting are A356 and 357. Other
aluminum alloys produced by semi-solid casting include A390, 319, 319S (a modified high
strength version of the conventional 319 composition), 380, and 355. In experimental trials,
other aluminum alloys have been produced by semi-solid casting, such as the casting alloy 206,
and wrought alloys from the 2xxx, 6xxx and 7xxx series. However, these are more sensitive to
hot tearing and have generally poorer mold filling ability.
The most common magnesium alloys produced by semi-solid casting are similar to the die
casting alloys, AZ91, AM50 and AM60. These alloys have excellent mold filling capability,
good hot tearing resistance, and good mechanical properties after casting.
Because SSM material is handled in its “Semi-Solid” state, hypereutectic Al-Si alloys and
particulate - reinforced Metal Matrix Composites (MMC) are less likely to segregate during
forming. These material also make good SSM candidates.

2 Aluminum Alloys

Note: Chemistries are given

for Aluminum Association
2.1 Cross Referencing of Aluminum Alloy Designations
(AA) designations. Propri-
etary alloys are typically held Table 3-1: Cross Reference of Aluminum Alloy Designations
to a tighter chemistry range.
Testing to obtain properties Commercial A356 357 355 319 319S A390 380
for high vacuum die casting
was performed on propri-
etary alloys. This data can AA A356.0 357.0 355.0 319.0 A390.0 380.0
be used as typical for the
AA alloys, but it should be
understood that differences UNS A13560 A03570 A03550 A03190 A13900 A03800
in chemistry can lead to
variations in properties.

Table 3-2: Cross Reference of Proprietary High Vacuum Aluminum-based

Alloys Commonly Used for High Vacuum Die Casting
Proprietary Silafont Mercalloy Mercalloy
Aural-2 Aural-3 Aural-5
Alloy Name 36 367 368

AA 365 A365 A365 367 368 374

Note: Proprietary alloys are typically held to tighter element ranges in the chemistry composition. This can lead to more consistent
properties in the alloy.

2.2 High Vacuum Die Casting

2.2.1 Chemical Composition for High Vacuum Casting
Table 3-3: Chemical Composition of Some of the Aluminum-based Alloys Commonly
Used for High Vacuum Die Casting
Alloy
Si Fe Cu Mn Mg Zn Ti Other
Name
Each Total
365 9.5-11.5 0.15 0.03 0.50-0.80 0.10-0.50 0.07 0.04-0.15 0.03 0.10
A365 9.5-11.5 0.15-0.25 0.02 0.30-0.60 0.10-0.60 0.03 0.10 0.05 0.15
367 8.5-9.5 0.25 0.25 0.25-0.35 0.30-0.50 0.10 0.20 0.05 0.15
368 8.5-9.5 0.25 0.25 0.25-0.35 0.10-0.30 0.10 0.20 0.05 0.15
374 6.5-8.5 0.10-0.25 0.02 0.35-0.70 0.10-0.40 0.03 0.04-0.15 0.05 0.05

3-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
Generic alloy names are provided. Primary alloy producers may have proprietary alloys that fit
inside the chemistry ranges provided. Proprietary alloys may have slightly different properties.
High vacuum die casting is injected at high speeds like in conventional die casting, so die
soldering is a major issue due to the affinity of aluminum to iron (die steel) during injection. In
conventional die casting alloys this is avoided through the high Fe content (around 1%) in typical
alloys. In order to achieve high ductility it is necessary to lower the Fe content to below 0.25% so
the Fe is replaced by Mn at levels of 0.25% to 0.8% and in some alloys (with the lower end of the
Mn range) through the addition of Sr at 500-700ppm.

2.2.2 Mechanical Properties of High Vacuum Die Casting - F -Temper

Table 3-4: Mechanical Properties of High Vacuum Die Castings in the F-Temper (as cast)
Aural 2 Aural 3 Mercalloy 367 Mercalloy 368 Silafont 36
3
Property
(A365) (A365) (367) (368) (365)
Yield Strength
ksi 17-22 19-23 17-19 18-20 17-22
MPa (120-150) (130-160) (112-131) (125-140) (120-150)

UTS
ksi 36-45 36-45 38-40 38-40 36-42
MPa (250-310) (250-310) (260-275) (260-276) (250-290)
Elongation (%) 5-10 4-8 8 10-12 5-11
Typical values are provided. Possibility for property changes due to product design and process controls.

2.2.3 Mechanical Properties of High Vacuum Die Casting - T5 -Temper

Table 3-5: Mechanical Properties of High Vacuum Die Castings Heat
Treated to the T5 - Temper Property
Aural 2 Aural 3 Mercalloy 367 Silafont 36
Property
(A365) (A365) (367) (365)
Yield Strength
ksi 22-28 28-35 25-30 23-36
MPa (150-190) (190-240) (170-205) (155-245)

UTS
ksi 39-44 44-49 43-45 40-49
MPa (270-300) (300-340) (295-310) (275-340)
Elongation (%) 6.5-9 4-6.5 5.0-9.0 4-9
Typical values are provided. Possibility for property changes due to product design and process controls.

2.2.4 Mechanical Properties of High Vacuum Die Casting - T6/7 -Temper

Table 3-6: Mechanical Properties of High Vacuum Die Castings Heat Treated
to the T6/7 - Temper
Aural 2 Aural 3 Mercalloy 367 Mercalloy 368 Silafont 36
Property
(A365) (A365) (367) (368) (365)
Heat Treatment Auraltherm - 2 (T7) Auraltherm - 3 (T7) T6 T6 T6
Yield Strength
ksi 17-20 20-32 33-35 27-29 30-41
MPa (120-140) (140-220) (230-245) (185-200) (210-280)

UTS
ksi 29-32 31-41 41-45 41-43 42-49
MPa (200-220) (210-280) (285-310) (280-295) (290-340)
Elongation (%) 14-18 6-14 8-10 14-16 7-12
Typical values are provided. Possibility for property changes due to product design and process controls.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-5
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.3 Squeeze Casting
Squeeze castings are generally used after heat treating to the T6 temper, although they are
occasionally used in the F-temper (as-cast). Unlike semi-solid castings, squeeze castings are not
used after heat treating to the T5 temper, as castings made from fully liquid alloys generally have
low ductilities in the T5 temper.

2.3.1 Chemical Composition for Squeeze Casting and Semi-Solid Casting

Table 3-7: Detailed Chemical Composition of Aluminum Alloys for Squeeze and Semi-Solid Casting

Element* A356 357 355 319 319S** A390 380 383

Silicon (Si) 6.5-7.5 6.5-7.5 4.5-5.5 5.5-6.5 5.5-6.5 16.0-18.0 7.5-9.5 9.5-11.5

Iron (Fe) 0.20 0.15 0.60 1.0 0.15 0.50 2.0 1.3

Copper (Cu) 0.20 0.50 1.0-1.5 3.0-4.0 2.5-3.5 4.0-5.0 3.0-4.0 2.0-3.0

Manganese
0.10 0.03 0.50 0.50 0.03 0.10 0.50 0.10
(Mn)
Magnesium
0.25-0.45 0.45-0.60 0.40-0.60 0.10 0.30-0.40 0.45-0.65 0.10 0.50
(Mg)

Nickel (Ni) 0.35 0.03 0.50 0.30

Zinc (Zn) 0.10 0.05 0.35 1.0 0.05 0.10 3.0 3.0

Lead (Pb)+
0.03 0.35 0.15
Tin (Sn)
Titanium
0.20 0.20 0.25 0.25 0.20 0.20 -
(Ti)
Strontium
0.01-0.05 -
(Sr)

Other (each) 0.05 0.05 0.05 0.03 0.10 0.50

Other (total) 0.15 0.15 0.15 0.50 0.10 0.20 0.50 Bal.

Aluminum
Bal. Bal. Bal. Bal. Bal. Bal. Bal.
(Al)
*Wt% **319S may be obtained from SAG

3-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.3.2 Mechanical Properties of Squeeze Castings — F-Temper
Table 3-8: Mechanical Properties of Squeeze Castings
in the F-Temper (as cast)
Property 380 383*

Yield Strength
23 145 – 159
ksi
(160) (21.0 – 23.0)
(MPa)
UTS
38 269 – 290
ksi
(262) (39.0 – 42.0)
(MPa)
Elongation
3
2 2.8 – 3.5
%
Impact Strength
1.5
ft-lbs
(2)
( J)
Young’s Modulus
10.3
psi x 106
(71)
(GPa)
Typical values are provided. Possibility for property changes due to product design and process controls.
*Data for 383 alloy is from Contech study which used round tensile bars with 0.25 inch diameter and
1.0 inch long gauge length

2.3.3 Mechanical Properties of Squeeze Castings — T6-Temper

Table 3-9: Mechanical Properties of Squeeze Castings Heat Treated
to the T6-Temper
Property A356 357 383* 390

Yield Strength
33 36 296 – 317
ksi N/A
(228) (248) (43.0 – 46.0)
(MPa)
UTS
44 48 379 – 421 54
ksi
(303) (331) (55.0 – 61.0) (372)
(MPa)
Elongation
12 9 3.0 – 5.0 <1
%
Hardness
90 140
BHN
Impact Strength
12 9
ft-lbs
(16) (12)
( J)
Fatigue Strength
14
ksi
(97)
(MPa)
Young’s Modulus
10.5 10.5 11.8
psi x 106
(72) (72) (81)
(GPa)
Typical values are provided. Possibility for property changes due to product design and process controls.
*Data for 383 alloy is from Contech study which used round tensile bars with 0.25 inch diameter and
1.0 inch long gauge length

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-7
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.4 Semi-Solid Casting Properties
Alloys used in the Semi-Solid process are noted in table 3-7.
Semi-solid castings are most typically used in the T5-temper although they can also be used as
cast (F-temper) or after heat treating to the T6 temper.

2.4.1 Processing Information for Thixocasting and Rheocasting — T5 Temper

Typical T5 heat treatment conditions for thixocast and rheocast aluminum alloys are listed in
Table 3-10. For the T5-temper, the castings must be water quenched as soon as possible and no
longer than 15-30 seconds after removal from the casting die, and then aged using conditions
such as those listed in Table 3-10. Rapid ejection and immediate quenching is encouraged in
order to achieve significantly improved properties over the F temper.
2.4.2 Processing Information for Thixocasting and Rheocasting — T6 Temper
Typical T6 heat treatment conditions for thixocast and rheocast aluminum alloys are listed in

Table 3-10: Processing Information for T5-Temper of Thixocasting and Rheocasting

Alloy Typical Aging Conditions

A356 6-12 hrs @ 320°F (160°C)

357 6 hrs @ 338°F (170°C)

355 10 hrs @ 338°F (170°C)

Table 3-11. When heat treating to the T6-temper, it is not critical whether the castings are
air cooled or water quenched after removal from the casting die. However, the castings must
be quenched into water within 15-30 seconds after removal from the solution heat treatment
furnace.

Table 3-11: Processing Information for T6-Temper of Thixocasting and Rheocasting

Alloy Solution Heat Treatment Conditions Typical Aging Conditions

A356 4-10 hrs @ 1000°F (540°C) 3-6 hrs @ 320°F (160°C)

357 10 hrs @ 1000°F (540°C) 6 hrs @ 338°F (170°C)

319 4 hrs @ 930°F (500°C) 4 hrs @ 338°F (170°C)

319S 6 hrs @ 930°F (500°C) 10 hrs @ 338°F (170°C)

A390 6 hrs @ 930°F (500°C) 6 hrs @ 338°F (170°C)

380 8 hrs @ 940°F (505°C) 3 hrs @ 310°F (155°C)

3-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.4.3 Mechanical Properties of Thixocast Aluminum Alloys Heat Treated to T5 Temper
Table 3-12: Mechanical Properties of Thixocastings Heat Treated to the T5-Temper
Property A356 357 355

Yield Strength
26 29 33
ksi
(179) (200) (228)
(MPa)
UTS
36 41 46
ksi
(248) (283) (317)
(MPa)
Elongation
%
10 8 7 3
Hardness
89 90
BHN
Fatigue Strength
13.5
ksi
(93)
(MPa)
Young’s Modulus
10.5 10.5 10.2
psi x 106
(72) (72) (70)
(GPa)
Typical values are provided. Possibility for property changes due to product design and process controls.

2.4.4 Mechanical Properties of Thixocast Aluminum Alloys Heat Treated to T6 Temper

Table 3-13: Mechanical Properties of Thixocastings Heat Treated to the T6-Temper
Property A356 357 319S A390

Yield Strength
33 41 46
ksi N/A
(228) (283) (317)
(MPa)
UTS
44 50 58 50
ksi
(303) (345) (400) (345)
(MPa)
Elongation
12 9 5 <0.2
%
Hardness
119
BHN
Impact Strength
14 8 14
ft-lbs
(97) (55) (97)
( J)
Fracture Toughness,
KQ 20 20.5
ksi√in
Fatigue Strength
23.8*
ksi
(164)*
(MPa)
Young’s Modulus
10.5 10.5 11.8
psi x 106
(72) (72) (81)
(GPa)
*107 cycles
Typical values are provided. Possibility for property changes due to product design and process controls.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-9
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.4.5 Mechanical Properties of Rheocast Aluminum Alloys in the F-Temper
Table 3-14: Mechanical Properties of Rheocastings in the F-Temper (as cast)
Property 319 A356

Yield Strength
19 16
ksi
(131) (110)
(MPa)
UTS
34 35
ksi
(234) (241)
(MPa)
Elongation
4 13
%
Typical values are provided. Possibility for property changes due to product design and process controls.

2.4.6 Mechanical Properties of Rheocast Aluminum Alloys Heat Treated to the T5 Temper
Table 3-15: Mechanical Properties of
Rheocastings Heat Treated to the T5-Temper
Property A356

Yield Strength
26
ksi
(179)
(MPa)
UTS
39
ksi
(269)
(MPa)
Elongation
7
%
Young’s Modulus
10.5
psi x 106
(72)
(GPa)
Typical values are provided. Possibility for property changes
due to product design and process controls.

2.4.7 Mechanical Properties of Rheocast Aluminum Alloys Heat Treated to the T6 Temper
Table 3-16: Mechanical Properties of Rheocastings
Heat Treated to the T-6 Temper
Property A356 357 319

Yield Strength
34 42 22
ksi
(234) (290) (152)
(MPa)
UTS
45 50 37
ksi
(310) (345) (255)
(MPa)
Elongation
13 7 6
%
Young’s Modulus
10.5 10.5 10.7
psi x 106
(72) (72) (74)
(GPa)
Typical values are provided. Possibility for property changes due to
product design and process controls.

3-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
2.5 Physical Properties of Aluminum Alloys Commonly Used for
Squeeze Casting & Semi-Solid Casting
The values shown below in Table 3-17 are taken from the NADCA Product Specification
Standards for High Pressure Die Casting and the Metals Handbook for castings produced by
die casting, sand, or permanent mold casting. However, these values should be representative of
values for squeeze and semi-solid castings.

Table 3-17: Physical Properties of Squeeze and Semi-Solid Aluminum Alloys

Element A356 357 355 319 A390 380
Density
lbs/in3
0.097
(2.69)
0.097
(2.69)
0.098
(2.71)
0.101
(2.80)
0.099
(2.74)
0.098
(2.71)
3
(g/cm3)
Melting
Range 1030-1140 1030-1140 1010-1150 960-1125 940-1200 1000-1100
°F (555-615) (555-615) (545-620) (515-605) (505-650) (540-595)
(°C)
Specific
Heat 0.230 0.230 0.230 0.230 0.230
BTU/lb°F (963) (963) (963) (963) (963)
(J/kg°C)
Coeff. Of
Thermal
11.9 12.0 12.4 11.9 10.0 12.2
Expansion
(21.6) (21.8) (22.5) (21.6) (18.0) (22.0)
µ in/in°F
(µ m/m°K)
Poisson’s
0.33 0.33 0.33 0.33
Ratio

3 Magnesium Alloys

3.1 Cross Referencing of Magnesium Alloy Designations

Most thixomolding components are made from three magnesium alloys, AZ91D, AM-60
and AM-60.

Table 3-18: Cross Reference of Magnesium Alloy Designation

Commercial AZ91D AM-50 AM-60

UNS M11916 M10600

DIN 1729 3.5662.05

JIS
H 2222 & MDI1D MDI2A
H 5303

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-11
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
3.2 Chemical Composition of Magnesium Alloys for Thixomolding
Table 3-19: Chemical Composition of Magnesium
Alloys Used for Thixomolding
Element* AZ91D AM-50 AM-60

Aluminum (Al) 8.3-9.7 4.4-5.4 5.5-6.5

Zinc (Zn) 0.35-1.0 0.22 max 0.22 max

Manganese (Mn) 0.15-0.50† 0.26-0.6† 0.24-0.6†

Silicon (Si) 0.10 max 0.10 max 0.10 max

Iron (Fe) 0.005† 0.004† 0.005†

Copper (Cu), Max 0.030 0.010 0.010

Nickel (Ni), Max 0.002 0.002 0.002

Others Total 0.02 0.02 0.02

Magnesium (Mg) Balance Balance Balance

*Wt%
†
If either of the minimum manganese limit or the maximum iron limit is
not met, then the iron/manganese ratio shall not exceed 0.032 for AZ91D,
0.015 for AM-50 and 0.021 for AM-60

3.3 Processing Information for Thixomolded Magnesium Components

Most thixomolded components are used in the F-temper.

3-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
3.4 Mechanical Properties of Thixomolded Magnesium Components
Table 3-20: Mechanical Properties of Thixomold Castings
Property AZ91D AM-50 AM-60

Yield Strength
23 18 19
ksi
(159) (124) (131)
(MPa)
UTS
34 32 32
ksi
(234) (220) (220)
(MPa)
Elongation
%
3-6 6-13 6-9 3
Hardness
63 65
BHN
Shear Strength
20
ksi
(138)
(MPa)
Impact Strength
6.6 6.2
ft-lbs
(8.9) (8.4)
( J)
Fatigue Strength
14 10-13
ksi
(97) (69-90)
(MPa)
Young’s Modulus
6.5 6.5 6.5
psi x 106
(45) (45) (45)
(GPa)
Typical values are provided. Possibility for property changes due to product design and process controls.

3.5 Physical Properties of Magnesium Thixomolded Components

Table 3-21: Physical Properties of Thixomold Magnesium Alloys
Property AZ91D AM-50 AM-60

Density
0.066 0.064 0.065
lbs/in3
(1.81) (1.78) (1.79)
(g/cm3)
Melting Range
875-1105 1010-1150 1005-1140
°F
(470-595) (543-620) (540-615)
(°C)
Specific Heat
0.25 0.25 0.25
BTU/lb °F
(1.05) (1.05) (1.05)
( J/kg°C)
Coeff. Of Thermal
Expansion 13.8 14.4 14.2
µ in/in°F (25.0) (26.0) (25.6)
(µ m/m°K)
Thermal
Conductivity 42 36 36
BTU/ft hr °F (72) (62) (62)
(W/m °K)
Electrical Resistivity
(14.1) (12.5) (12.5)
(µΩcm)

Poisson’s Ratio 0.35 0.35 0.35

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-13
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings
Table 3-22: Typical Properties for Cast Aluminum Alloys Produced by the
Squeeze and SSM Processes

SSM Cast
Squeeze Cast Thixocast
380-F A356-T6 357-T6 390-T6 355-T5 A356-T5 357-T5 319S-T6
Yield Strength
ksi 23 33 36 N/A 33 26 29 46
(MPa) (160) (228) (248) N/A (228) (179) (200) (317)
Ultimate Tensile
Strength
ksi 38 44 48 54 46 36 41 58
(MPa) (262) (303) (331) (372) (317) (248) (283) (400)
Elongation
% 2 12 9 <1 7 10 8 5
Hardness
HBN 90 140 89 90 119
Impact Strength
ft-lbs 1.5 12 9 13.5 14
(J) (2) (16) (12) (93) (97)
Fatigue Strength
ksi 14 23.8*
(MPa) (97) (164*)
Young’s Modulus
psi x 10 6 10.3 10.5 10.5 11.8 10.2 10.5 10.5 10.2
(GPa) (71) (72) (72) (81) (70) (72) (72) (70)
Density
lbs/in3 0.098 0.097 0.097 0.098 0.098 0.097 0.097
(g/cm ) 3
(2.71) (2.69) (2.69) (2.73) (2.71) (2.69) (2.69)
Melting Range
°F 1000-1100 1030-1140 1030-1140 950-1200 1010-1150 1030-1140 1030-1140
(°C) (540-595) (555-615) (555-615) (510-650) (545-620) (555-615) (555-615)
Specific Heat
BTU/lb°F 0.230 0.230 0.230 0.230 0.230 0.230
(J/kg°C) (963) (963) (963) (963) (963) (963)
Coeff of Thermal Exp.
μ in/in°F 12.2 11.9 12.0 10 12.4 11.9 12.0
(μ m/m°K) (22.0) (21.6) (21.8) (18.0) (22.5) (21.6) (21.8)
Poisson’s Ratio 0.33 0.33 0.33 0.33
*10 cycles
7

Typical values are provided. Possibility for property changes due to product design and process controls.

3-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings

SSM Cast
Thixocast Rheocast
A356-T6 357-T6 A390-T6 319-F A356-F A356-T5 319-T6 A356-T6 357-T6

33 41 N/A 19 16 26 22 34 42
(228) (283) N/A (131) (110) (179) (152) (234) (290)

3
44 50 50 34 35 39 37 45 40
(303 ) (345) (345) (234) (241) (269) (255) (310) (345)

12 9 <0.2 4 13 7 6 13 7

14 8
(97) (55)

10.5 10.5 11.8 10.5 10.7 10.5 10.5

(72) (72) (81) (72) (74) (72) (72)

0.097 0.097 0.099 0.101 0.097 0.097 0.101 0.097 0.097

(2.69) (2.69) (2.74) (2.8) (2.69) (2.69) (2.8) (2.69) (2.69)

1030-1140 1030-1140 940-1200 960-1125 1030-1140 1030-1140 960-1125 1030-1140 1030-1140

(555-615) (555-615) (505-650) (615-605) (555-615) (555-615) (515-605) (555-615) (555-615)

0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230

(963) (963) (963) (963) (963) (963) (963) (963)

11.9 12.0 10.0 11.9 11.9 11.9 11.9 11.9 12.0

(21.6) (21.8) (18.0) (21.6) (21.6) (21.6) (21.6) (21.6) (21.8)
0.33 0.33 0.33 0.33 0.33 0.33

NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021 3-15
 Chemical, Mechanical & Physical Properties of
High Vacuum, Squeeze, and Semi-Solid Die Castings

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3-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 3 / 2021
 4
Engineering & Design: Tolerancing section

Section Contents NADCA No. Format Page

Frequently Asked Questions (FAQ) 4-2
1 Introduction 4-2
2 Section Objectives 4-3
3 Standard and Precision Tolerances 4-3
4 Production Part Technologies 4-4
5 Die Casting, SSM & Squeeze Cast Part Design 4-6
6 Linear Dimensions Tolerances S-4-1-21 Standard 4-7
P-4-1-21 Precision 4-8
7 Parting Line Tolerances S-4-2-21 Standard 4-9
P-4-2-21 Precision 4-10
4
8 Moving Die Component Tolerances S-4-3-21 Standard 4-11
P-4-3-21 Precision 4-12
9 Angularity Tolerances S/P-4-4-21 Standard/Precision 4-13
10 Concentricity Tolerances S-4-5-21 Standard 4-17
P-4-5-21 Precision 4-18
11 Parting Line Shift S-4-6-21 Standard 4-19
12 Draft Tolerances S/P-4-7-21 Standard/Precision 4-21
13 Flatness Tolerances S-4-8-21 Standard 4-23
P-4-8-21 Precision 4-24
14 Design Recommendations: 4-25
Cored Holes As-Cast

15 Cored Holes for Cut Threads S-4-9-21 Standard 4-28

P-4-9-21 Precision 4-29
16 Cored Holes for Formed Threads P-4-10-21 Precision 4-30
17 Cored Holes for Pipe Threads S-4-11-21 Standard 4-32
18 Cast Threads S-4-12-21 Standard 4-33
19 Machining Stock Allowance S/P-4-13-21 Standard/Precision 4-34
20 Additional Considerations for Large Castings 4-36

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-1
 Engineering & Design: Tolerancing

Tolerance in any part is a

three-dimensional character- Frequently Asked Questions (FAQ)
istic. Many different types of
tolerance will be discussed
throughout sections 4. Most 1) W
 hat is the difference between Standard and Precision Tolerances?
feature tolerances will See pages 4-3 and 4-4, Standard and Precision Tolerances.
have Linear Tolerance in
combination with Projected 2) W hat is a Parting Line Shift?
Area Tolerance to give an See pages 4-19 and 4-20, Parting Line Shift.
overall feature “volumetric”
tolerance like Parting Line, 3) If my casting requires machining, how should the casting be dimensioned?
Moving Die Component See page 4-34 and 4-35, Machining Stock Allowances.
(MDC) and Angularity 4) How large should a cast-in hole be if threads need to be tapped or formed in the casting?
Tolerances.
See page 4-28 and 4-29, Cored Holes for Cut Threads. Also see pages 4-30 and 4-31,
Projected Area is the area of Cored Holes for Formed Threads.
a specific feature projected
into a plane. For parting 5) W hat type of draft should be used on exterior and interior walls?
line and parting line shift See page 4-21, Draft Requirements.
the Projected Area is the 6) W hat type of flatness tolerance can be expected on a cast surface?
open area of the die cavity
in the parting line plane. For See pages 4-23 and 4-24, Flatness Requirements.
example, if a die half was
laid down and filled with
liquid, the surface of the
liquid at the parting line is 1 Introduction
the Projected Area. For the
MDC, the Projected Area is
determined using the same Die casting requires a specific degree of precision for the end product to meet the requirements
method as for a parting line. of form, fit and function. However there is a cost associated with increased precision.
See the applicable figures in
the appropriate sections for Some of the costs associated with a higher degree of tolerance include:
Projected Area. • Decreased die life due to wear that puts die dimensions outside of specified high precision tolerance
Linear Tolerance is • More frequent die repair or replacement to maintain a high precision tolerance
calculated from a line
perpendicular to any feature. • More frequent shutdown (shorter production runs) to repair or replace dies
The Parting Line line is • More frequent part or die inspections to ensure high precision tolerance is maintained
the total depth of molten
material on both die halves, • Potential for higher scrap rate for not maintaining specified high precision tolerance
which is perpendicular to the
parting line plane. The MDC
A good casting design will take into account not only the precision required to meet the require-
line is the length of the core ments of form, fit and function, but will also take into account maximizing tolerance to achieve a
slide which is perpendicular longer die life and longer production runs with less inspections. This will result in less potential for
to the head of the core slide.
Length of a core slide is scrap and more acceptable parts because the tolerance range for acceptable parts has increased.
determined from the point In section 4 tolerance will be specified in two values. Standard Tolerance is the lesser degree of
where the core first engages
the die to its full insertion
precision that will meet most applications of form, fit and function. It is specified in thousandths of an
point. inch (0.001) or hundredths of a millimeter (0.01). Degree of variation from design specified values is
larger than that of Precision Tolerance as shown in graphical representation at the end of section 4.
Projected Area Tolerance
plus Linear Tolerance equals Precision Tolerance is a higher degree of precision used for special applications where form,
feature tolerance (tolerance fit and function are adversely affected by minor variations from design specifications. Precision
of the volume of the part). Tolerance is also specified in thousandths of an inch or hundredths of a millimeter. However, its
See Volumetric Tolerance variation from design specified values is less than that of Standard Tolerances.
diagram on the facing page. Examples of tolerance application may be an engine casting that uses Standard Tolerance.
Form, fit and function are not critical since moving parts will be encased in sleeves that are cast
into place. Variations in size will be filled with cast metal.
Standard Tolerance meets the criteria for this application as part of the design. However a gas line fit-
ting may require a higher degree of precision so that mating parts fit together to prevent leaks. Precision
gas fittings may cost more to produce because of the higher degree of precision that must be maintained.
Degree of precision depends on the applications of form, fit and function which resides with
the design engineer’s expectation of part performance.
Cast components can be specified and produced to an excellent surface finish, close dimen-
sional tolerances and to minimum draft, among other characteristics.
All of the capabilities of the casting process, specified to maximum degree, will rarely, if ever, be
required in one cast part. For the most economical production, the design engineer or specifier should
attempt to avoid such requirements in a single component.
It is important for the product designer and engineer to understand precisely how today’s die
casting process can be specified in accordance with the capabilities of the die casting industry.

4-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

2 Section Objectives Volumetric

Tolerance
The Engineering and Design Sections of this document are prepared to aid product specifiers in for Across
achieving the most cost-effective results through net-shape and near-net-shape casting produc-
tion. They present both English and Metric values on the same page.
Parting
Section 4 presents standard/precision tolerances and other specifications for die cast parts rang- Line Features
ing from a fraction of an inch (several millimeters) to several feet (meter) in size. Material weight (See diagram on this page.)
ranges from a fraction of an ounce (several milligrams) to tens of pounds (kilograms). Parting Line Projected Area
is defined by the horizontal
Sizes are for reference only. Die casters should be consulted on the size of casting they can produce. center line shown in the figure
Section 5 presents Geometric Dimensioning, which provides guidelines for applying tolerances below. Its dimensions are 1.00
to cast part specifications. inch wide by (7.50 - 1.50)
inches long. The Projected
These sections provide information for developing the most economically produced design that area is (1.00 x 6.00) or 6.00
meets the specifications of form, fit and function. in. sq. This is the surface
area used for features across
the parting line. Tolerance is
expressed in inches.
3 Standard and Precision Tolerances Linear Dimension (depth of
cavity on both die halves) is
1.40 inches. This is the linear
4
As noted in the contents for this section, seven important sets of tolerancing guidelines are dimension used to determine
presented here as both “Standard” and “Precision” Tolerances: Linear Tolerance.
• Linear dimensions Feature Tolerance is Pro-
• Dimensions across parting Lines jected Area Tolerance plus
Linear Area Tolerance.
• Dimensions formed by moving die components (MDC)
• Angularity
• Draft Graphical
• Flatness Representation
• Cored holes for threads Throughout section 4 there
The following features are only specified in Standard Tolerance. Unlike the features above, parts is graphical representation of
specific feature tolerances.
that exceed the following tolerances will not meet the requirements of form, fit and function. These Precision tolerances are
features are specified at the maximum tolerance to meet their requirements. These features include: generally closer to design
specifications than standard
• Concentricity tolerances. The x-axis along
• Parting Line Shift y-axis at zero indicates actual
design specification. Graph
lines indicate the maximum
allowable deviation from
design specification.

Volume = 6.64 in3

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-3
 Engineering & Design: Tolerancing

Cpk vs Cp
Demonstrable process capability requirements need to be discussed and agreed upon by the
customer and the caster for all new jobs. Cpk is the measurement commonly used to determine
if the process can produce the parts within specification. It is common in die casting for the
process to yield a high Cp while struggling for Cpk for a few dimensions. This is because the
casting may shrink or distort in un-anticipated ways. This can be particularly problematic for
large and thin castings.

Standard Tolerances
Standard Tolerances cover expected values consistent with high casting cycle speeds, uninter-
rupted production, reasonable die life and die maintenance costs, as well as normal inspection,
packing and shipping costs.
Such tolerances can normally be achieved by the widely available production capabilities of
casters practicing standard methods and procedures. Conformity to these standards by designers
assures the most predictable service and lowest cost.

Precision Tolerances
Critical requirements for dimensional accuracy, draft, etc.., beyond the Standard Tolerances
presented, can be specified when required.
Precision Tolerances are presented on the page following the Standard Tolerances for the same
characteristic. The values shown for Precision Tolerances represent greater casting accuracy. See
graphical comparison of Standard and Precision Tolerances throughout section 4. Part precision
tolerances involve extra precision in die construction and/or special process controls during
production. The use of new technologies and equipment aid in maintaining Precision Tolerance.
While early consultation with the caster can sometimes result in selected special precision requirements
being incorporated with little additional cost, such tolerances should be specified only where necessary.
It should be noted that the tolerances shown must, of necessity, be guidelines only—highly
dependent on the particular shape, specific features and wall thickness transitions of a given part
design. These factors, under the control of the product designer, greatly influence the ability of
the casting process to achieve predetermined specifications in the final cast part.
Where a number of critical requirements are combined in a single casting, early caster evalu-
ation of a proposed design is essential. Design modifications for more cost-efficient casting can
nearly always be made. Without such feedback, additional costs can usually be expected and the
design, as originally planned, may not be producible by die casting.
When specific designs are examined, tolerances even closer than the Precision Tolerances
shown can often be held by repeated production sampling and recutting of the die casting die,
together with production capability studies. While such steps will result in additional tooling
and production costs, the significant savings that can result by eliminating substantial secondary
machining and/or finishing operations can prove highly cost effective.
When attempting to hold tolerances closer than Precision Tolerances steel safe practrices
should be utilized when building dies and tooling.

Datums Placement
Proper use of dimensioning places all features in space relative to some datum structure.
Datums are best when they represent the functional requirements of the final product. All the
tolerance recommendations presented in this section are length/size dependent. Therefore, one
should take care when choosing the datum features.
• Things to consider when selecting datums
o Function of the part.
o Location of critical features relative to the datums
o Cross parting vs in parting dimensions vs moving die components

4-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

4 Production Part Technologies

This section presents advantages and limitations of various production technologies for a simple
part such as the one shown in Fig. 4-1. The section that follows presents the die cast alternative
and its advantages and limitations.

Fig. 4-1 Proposed component.

Metal Stamping Alternative

This part design, as pictured in Fig. 4-1 and if designed to a minimum thickness without
additional complexities, could be considered for volume production by the metal stamping process.
Metal stamping lends itself to high-speed production with infrequent die replacement or repair. 4
However, the stamping process can only produce features that are apparent on both sides of a thin
part. Indentations on one side of the part appear as ridges on the other side of the part. Critical
bends in the metal surface of stamped products become areas of weakness where metal is
formed to make the bend. Complex features within the layer of metal are impossible without
additional stamped parts and assembly. Thicker parts require higher stamping pressure which
compounds metal fatigue at critical bends. This is similar to a large tree snapping in the wind
where a sapling will bend. Multiple stamped layers and assembly would exceed the cost of the
die cast alternative.

Extrusion Alternative
If the part design required stock depth beyond stamping capabilities, the extrusion process
might be a production alternative for creating such a profile—unless complex additional interior
features were desirable, such as those shown in Fig. 4-1.
When total costs of a product assembly can be significantly reduced by a more robust part design,
as that suggested by Fig. 4-1, the production process which allows such design freedom is the
better choice. The extrusion process produces a uniform internal structure in one axis such as a bar
or a tube. End features or variations within the axis are impossible. A part, such as the one shown
in Fig. 4-1, has design feature variations on all axes therefore extrusion of this part is not possible
without multiple operations which would exceed the cost of the die cast alternative.

Machining Alternative
Automated machining could produce product features as shown in Fig. 4-1. Complex features
would require additional operations for each piece. This would be very time consuming and
would place tremendous wear on production equipment especially during large volume produc-
tion. As volumes increased, machining would become a very high-cost production option.

Foundry Casting Alternative

Foundry casting plus secondary machining might be an alternative for this part. Foundry casting
involves pouring molten metal into a mold. Without the pressure of die, SSM or squeeze casting
to force metal into critical paths, around tight turns, and into small features of the mold. Foundry
casting can not achieve the detail and precision of die, SSM or squeeze casting. The Foundry
casting process is relatively slow in that gravity fills and mold positions take time to achieve.
Extensive secondary machining is required for Foundry castings when close tolerances are
required. This is not only costly but time consuming. Foundry casting is usually reserved for large
iron castings with very little intricate detail. It is not considered as a high volume process. Net-
shape die casting can become the more cost-effective solution, often at low production volumes.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-5
 Engineering & Design: Tolerancing

Comment on Investment Casting Alternative

Theoretical Sharp At low volumes the investment casting process could be considered to achieve precision toler-
Corners and ances. At higher volumes die casting would be the clear choice.
Drafted Surfaces Powdered Metal Alternative
Die castings require draft
on surfaces parallel to the The powdered metal process offers dimensional accuracy for many parts. It cannot achieve the
pulling direction as well as
radii on most sharp corners. more complex configurations, detailed features or thinner walls which die casting can easily
This creates an opportunity produce to net or near-net shape.
for features that cannot be
directly measured. Other
cases may create situa- Plastic Molded Alternative
tions that are impractical
to measure. Concave radii Plastic injection molding could achieve the designed configuration shown in Fig. 4-1, but if
generally create a theoretical requirements of rigidity, creep resistance, and strength—particularly at elevated temperatures—
sharp intersection some-
where inside the casting were important, plastics would be questionable. The longevity of plastic components is normally
while convex shapes create substantially less than that of metal components. Plastics products are subject to failure modes such
a theoretical point in space.
Acceptable methods of as sunlight, radiation, heat and various chemicals. The designer needs to ensure that the application
measuring these features and duration of the end product will meet the customers needs and expectations. Additionally, the
should be discussed and preference for use of a recycled raw material as well as the potential for eventual recycling of the
agreed upon with the caster
and customer. Keep in mind product at the end of its useful life would also support a decision for die casting.
that 3D scanning technol-
ogy coupled with GD&T
based profile may be the best
method to clarify and satisfy 5 Die Casting, SSM and Squeeze Cast Part Design
the print requirements.

Fig. 4-1A, illustrates a good design practice for die, SSM and squeeze casting production.

Sharp corners have been eliminated and the design has been provided with the proper draft and
radii to maximize the potential die life and to aid in filling the die cavity completely under high
production cycle speeds.
Typical average wall thicknesses for a cast design range from 0.040 in. (1.016 mm) to 0.200 in.
(5.08 mm), depending on alloy, part configuration, part size and application.
Smaller castings with wall sections as thin as 0.020 in. (0.50 mm) can be cast, with die caster
consultation.
Dimensions are for reference. Some die casters can produce parts that are thicker or thinner than dimensions
listed. Consult a die caster to determine their limitations.
Fig. 4-1 will be used elsewhere in this section to present dimensional tolerances, specifically
as they relate to part dimensions on the same side of the die half, across the parting line, and
those formed by moving die components.
Note: Because dies wear over the course of producing castings, it should be noted that the number of shots on a die
prior to repair or replacement will be less for tighter casting tolerances and greater for wider casting tolerances.
Fig. 4-1 will also be used in the Geometric Dimensioning Section to show how datum structure can influence tool-
ing and tolerances.

F ig. 4-1A Proposed component with added features and design modified for cost-effective die casting production,
showing orientation in the die casting die and core slide (moving die component) to cast the additional f

4-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-1-21
STANDARD
TOLERANCES

6 Linear Dimensions: Standard Tolerances The values shown represent

Standard Tolerances, or
normal casting production
The Standard Tolerance on any of the features labeled in the adjacent drawing, dimension “E1” practice at the most economi-
cal level. For greater casting
will be the value shown in table S-4-1 for dimensions of features formed in the same die part. accuracy see Precision Toler-
Tolerance must be increased for dimensions of features formed by the parting line or by moving ances for this characteristic
on the facing page. Be sure
die parts to allow for movement such as parting line shift or the moving components in the die to also address the proce-
itself. See tables S-4-2 and S-4-3 for calculating tolerance of moving die components or parting dures referred to in Section
line shift. Linear tolerance is only for fixed components to allow for growth, shrinkage or minor 7, “Quality Assurance,” sub-
section 3, 4 and 5.
imperfections in the part.
Tolerance is the amount of variation from the part’s nominal or design feature. Significant numbers indicate
For example, a 5 inch design specification with ±0.010 tolerance does not require the amount the degree of accuracy in
calculating precision. The
of precision as the same part with a tolerance of ±0.005. The smaller the tolerance number, more significant numbers
the more precise the part must be (the in a specified tolerance,
the greater the accuracy.
higher the precision). Normally, the Significant number is the first
higher the precision the more it costs to E1 non-zero number to the right
manufacture the part because die wear of the decimal and
will affect more precise parts sooner.
all numbers to the right of
that number. For example, 4
Production runs will be shorter to allow 0.014. The degree of
E1 accuracy is specified by the
for increased die maintenance. Therefore three significant numbers
the objective is to have as much tolerance PL 0, 1, 4. This is not to be
as possible without affecting form, fit confused with tolerance pre-
cision. A tolerance limit of
and function of the part. 0.007 has a higher degree of
Example: precision because it is closer
to zero tolerance. Zero toler-
Aluminum Casting *GD&T is required for radii and chamfers ance indicates that the part
E1 = 5.00 in (127 mm) meets design specifications
exactly. Linear Standard and
Linear Precision tolerances
Standard Tolerance (from Table S-4-1) are expressed in thousandths
First inch (25.4 mm) ±.010 in (±0.25 mm) of an inch (.001) or hun-
dredths of a millimeter (.01).
Each additional inch (25.4 mm) 4x ±.001 in (±0.025 mm)
±.014 in (±0.35 mm)*
Notes:
*Note that .014 in converts to 0.36 mm. Significant digits and conversions can cause variations in final tolerance. Casting configuration and
shrink factor may limit some
Linear dimension tolerance only applies to linear dimensions formed in the same die half dimension control for achiev-
ing a specified precision.
with no moving components.
Linear tolerances apply to radii and diameters as well as wall thicknesses.

Table S-4-1 Tolerances for Linear Dimensions (Standard)

In inches, two-place decimals (.xx); In millimeters, single-place decimals (.x)

Casting Alloys
Length of Dimension "E1" Zinc Aluminum Magnesium Copper

Basic Tolerance ±0.010 ±0.010 ±0.010 ±0.014

up to 1" (25.4mm) (±0.25 mm) (±0.25 mm) (±0.25 mm) (±0.36 mm)
Additional Tolerance ±0.001 ±0.001 ±0.001 ±0.003
for each additional inch over 1" (25.4mm) (±0.025 mm) (±0.025 mm) (±0.025 mm) (±0.076 mm)

Note: Because dies wear over the course of producing castings, it should be noted that the number of shots on a die
prior to repair or replacement will be less for tighter casting tolerances and greater for wider casting tolerances.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-7
 NADCA Engineering & Design: Tolerancing
P-4-1-21
PRECISION
TOLERANCES
The Precision Tolerance
values shown represent
Linear Dimensions: Precision Tolerances
greater casting accuracy
involving extra precision Precision Tolerance on any of the features labeled in the adjacent drawing, dimension “E1”
in die construction and/or
special control in production. will be the value shown in table P-4-1 for dimensions between features formed in the same die
They should be specified part. Tolerance must be increased for dimensions of features formed by the parting line or by
only when and where neces-
sary, since additional costs moving die parts to allow for movement
may be involved. Be sure to such as parting line shift or the moving
also address the procedures E1
referred to in Section 7, components in the die itself. See tables
“Quality Assurance,” sub- P-4-2 and P-4-3 for calculating precision
section 3, 4 and 5.
of moving die components or parting line
shift. Linear tolerance is only for fixed E1
Methods for components to allow for growth, shrinkage
Improving or minor imperfections in the part.
PL
Precision: Example:
1. By repeated sampling Aluminum Casting
and recutting of the E1 = 5.00 in (127 mm)
die cast tool, along *GD&T is required for radii and chamfers
with capability studies,
even closer dimensions Precision Tolerance (from Table P-4-1)
can be held. However,
additional sampling First inch (25.4 mm) ±.002 in (±0.05 mm)
and other costs may be Each additional inch (25.4 mm) 4x ±.001 in (±0.025 mm)
incurred.
±.006 in (±0.15 mm)
2. For zinc die castings,
tighter tolerances can be
held, depending on part Linear tolerances apply to radii and diameters as well as wall thicknesses.
configuration and the Linear dimension tolerance only applies to linear dimensions formed in the same die half with no
use of artificial aging.
Artificial aging (also
moving components.
known as heat treating) Table P-4-1 Tolerances for Linear Dimensions (Precision)
may be essential for In inches, three-place decimals (.xxx); In millimeters, two-place decimals (.xx)
maintaining critical
dimensions in zinc, Casting Alloys
particularly if the part Length of Dimension "E1" Zinc Aluminum Magnesium Copper
is to be machined, due
to the creep (growth) Basic Tolerance ±0.002 ±0.002 ±0.002 ±0.007
characteristics of zinc. up to 1" (25.4mm) (±0.05 mm) (±0.05 mm) (±0.05 mm) (±0.18 mm)
The die caster should be
consulted during the part Additional Tolerance ±0.001 ±0.001 ±0.001 ±0.002
design stage. for each additional inch over 1" (25.4mm) (±0.025 mm) (±0.025 mm) (±0.025 mm) (±0.05 mm)

Note: Because dies wear over the course of producing castings, it should be noted that the number of shots on a die
prior to repair or replacement will be less for tighter casting tolerances and greater for wider casting tolerances.
Linear Tolerance
0.05

0.045 Al, Mg, Zn Stand. Tol.

Cu Stand. Tol.
0.04
Al, Mg, Zn Precis. Tol.
Tolerance in +/- Inches

0.035 Cu Precis. Tol.

0.03

0.025

0.02

0.015

0.01

0.005

0
1 2 3 4 5 6 7 8 9 10 11 12
(25.4) (50.8) (76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Dimension in Inches (mm)

4-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-2-21
STANDARD
TOLERANCES

7 Parting Line: Standard Tolerances The values shown represent

Standard Tolerances, or
normal die casting produc-
Parting Line Tolerance is the additional tolerance needed for cross parting line dimensions in tion practice at the most
economical level. For
order to account for die separation (die blow).. This is not to be confused with Parting Line Shift greater casting accuracy
Tolerance (cavity mismatch) which is the maximum amount die halves shift from side to side in see Precision Tolerances
for this characteristic on
relation to one another. the facing page. Be sure to
Parting Line Tolerance is a function of the also address the procedures
Projected Area of the part. The Projected Area is referred to in Section 7,
“Quality Assurance,” sub-
a two dimensional area measurement calculated section 3, 4 and 5.
by projecting the three dimensional part onto
a plane, which in this case is the cavity surface
at the parting line. An easy way to visualize Die Shift:
the Projected Area is by what shadow a casting
Parting line die shift, unlike
would project onto the cavity surface. parting line separation and
The Parting Line Tolerance is always a plus moving die component
tolerances, is a left/right
tolerance since a completely closed die has 0
separation. Excess material and pressure will
relationship with possible
± consequences. It can shift
in four directions, based
4
force the die to open along the parting line plane
on a combination of part
creating an oversize condition. The excess pressure will cause the part to be thicker than the ideal features, die construction
specification. It is important to understand that Table S-4-2 (Parting Line Tolerance) does not and operation factors. It
provide the Total Cross Parting Line Tolerance by itself. The Total Cross Parting Line Tolerance can occur at any time and
its tolerance consequences
for any dimension is the sum of the Linear Tolerance (derived from the part thickness) in addition should be discussed with
to the Parting Line Tolerance. the die caster at the design
stage to minimize any
Thus, information from the Parting Line Tolerance table S-4-2 in combination with the formerly impact on the final die
discussed Linear Tolerance table S-4-1 give a true representation of Total Cross Parting Line casting.
Tolerance. Note that the tolerances in the table apply to a single casting regardless of the number of
cavities. Notes:
Example: An aluminum die casting has 75 in 2 (483.9 cm 2) of Projected Area on the parting die All values for part dimen-
sions which run across the
plane. From table S-4-2, the Parting Line Tolerance is +0.012. This is combined with the total part die parting line are stated
thickness tolerance from table S-4-1 to obtain the Total Cross Parting Line Tolerance. as a “plus” tolerance only.
The die casting die at a die
The total part thickness including both die halves is 5.00 in. (127 mm) which is measured per- closed position creates the
pendicular to the parting die plane (dimension “E2 E1”). From table S-4-1, the Linear Tolerance bottom of the tolerance
is ±0.010 for the first inch and ±0.001 for each of the four additional inches. The Linear Tolerance range, i.e., 0.000 (zero).
Due to the nature of the die
of ±0.014 inches is combined with the Parting Line Tolerance of +0.012 to yield a Standard Cross casting process, dies can
Parting Line Tolerance of +0.026/-0.014 in. or in metric terms ±0.35 mm from Linear Tolerance separate imperceptibly at
the parting line and create
table S-4-1 plus +0.30 mm from Parting Line Tolerance table S-4-2 = +0.65/-0.35 mm. only a larger, or “plus” side,
tolerance.

Table S-4-2 Parting Line Tolerances (Standard) — Added to Linear Tolerances

Projected Area of Die Casting Casting Alloys (Tolerances shown are "plus" values only)
inches2 (cm2) Zinc Aluminum Magnesium Copper

up to 10 in2 +0.0045 +0.0055 +0.0055 +0.008

(64.5 cm2) (+0.114 mm) (+0.14 mm) (+0.14 mm) (+0.20 mm)

11 in2 to 20 in2 +0.005 +0.0065 +0.0065 +0.009

(71.0 cm2 to 129.0 cm2) (+0.13 mm) (+0.165 mm) (+0.165 mm) (+0.23 mm)

21 in2 to 50 in2 +0.006 +0.0075 +0.0075 +0.010

(135.5 cm2 to 322.6 cm2) (+0.15 mm) (+0.19 mm) (+0.19 mm) (+0.25 mm)
51 in2 to 100 in2 +0.009 +0.012 +0.012
(329.0 cm2 to 645.2 cm2) (+0.23 mm) (+0.30 mm) (+0.30 mm)
101 in2 to 200 in2 +0.012 +0.018 +0.018
(651.6 cm2 to 1290.3 cm2) (+0.30 mm) (+0.46 mm) (+0.46 mm)
201 in2 to 300 in2 +0.018 +0.024 +0.024
(1296.8 cm2 to 1935.5 cm2) (+0.46 mm) (+0.61 mm) (+0.61 mm)

For projected area of die casting over 300 in2 (1935.5 cm2), consult with your die caster.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-9
 NADCA Engineering & Design: Tolerancing
P-4-2-21
PRECISION
TOLERANCES
The Precision Tolerance
values shown represent
Parting Line: Precision Tolerances
greater casting accuracy
involving extra precision Precision Tolerances on dimensions such as “E2 E1”, which are perpendicular to (across) the die
in die construction and/or
special control in production. parting line, will be the linear dimension tolerance from table P-4-1 plus the value shown in
They should be specified table P-4-2. The value chosen from the table below depends on the “projected area” of the part,
only when and where neces-
sary, since additional costs
in inches squared or millimeters squared, in the plane of the die parting. Note that the tolerances
may be involved. Be sure to shown below are “plus side only” and based
also address the procedures on a single cavity die casting die.
referred to in Section 7,
“Quality Assurance,” sub- Example: An aluminum die casting has
section 3, 4 and 5. PL 75 in 2 (483.9 cm 2) of Projected Area on the
parting die plane. From table P-4-2, Parting
E2E1 Line Tolerance is +0.008. This is combined
Methods for *GD&T is required for radii and chamfers
with the total part thickness tolerance from
Improving table P-4-1 to obtain the Total Cross Parting
Line Tolerance.
Precision: Total part thickness including both die halves is 5.000 in. (127 mm) which is measured perpendicu-
1. Achieving precision lar to the parting die plane (dimension “E2 E1”). From table P-4-1, the Linear Tolerance is ±0.002
tolerancing often requires
welding and recutting for the first inch and ±0.001 for each of the four additional inches. The Linear Tolerance of ±0.006 is
the die inserts to more combined with the Parting Line Tolerance of +0.008 to yield a Precision Cross Parting Line Tolerance
closely match the print of +0.014/-0.006 in. or in metric terms (±0.15 mm plus +0.20 mm) = +0.35/-0.15 mm on dimensions
dimensions. This
practice may reduce the that are formed across the parting line.
life of the die casting
die. This is especially Table P-4-2 Parting Line Tolerances (Precision) — Added to Linear Tolerances
true when specialized
Projected Area of Die Casting Die Casting Alloys (Tolerances shown are "plus" values only)
die materials, treatments,
and/or coatings are inches2 (cm2) Zinc Aluminum Magnesium Copper
necessary to preserve the
die life. The potential up to 10 in2 +0.003 +0.0035 +0.0035 +0.008
reduced die life should (64.5 cm2) (+0.076 mm) (+0.089 mm) (+0.089 mm) (+0.20 mm)
be discussed and agreed
upon prior to correcting 11 in2 to 20 in2 +0.0035 +0.004 +0.004 +0.009
(71.0 cm2 to 129.0 cm2) (+0.089 mm) (+0.102 mm) (+0.102 mm) (+0.23 mm)
tooling to achieve tighter
dimensional capability. 21 in2 to 50 in2 +0.004 +0.005 +0.005 +0.010
(135.5 cm2 to 322.6 cm2) (+0.102 mm) (+0.153 mm) (+0.153 mm) (+0.25 mm)
2. For zinc die castings,
tighter tolerances can be 51 in2 to 100 in2 +0.006 +0.008 +0.008
held, depending on part (329.0 cm2 to 645.2 cm2) (+0.153 mm) (+0.203 mm) (+0.203 mm)
configuration and the
use of artificial aging. 101 in2 to 200 in2 +0.008 +0.012 +0.012
Artificial aging (also (651.6 cm2 to 1290.3 cm2) (+0.203 mm) (+0.305 mm) (+0.305 mm)
known as heat treating)
may be essential for 201 in2 to 300 in2 +0.012 +0.016 +0.016
maintaining critical (1296.8 cm2 to 1935.5 cm2) (+0.305 mm) (+0.406 mm) (+0.406 mm)
dimensions in zinc,
particularly if the part For projected area of die casting over 300 in2 (1935.5 cm2), consult with your die caster.
is to be machined, due
to the creep (growth) Parting Line Tolerances
characteristics of zinc. 0.03
The die caster should be
consulted during the part Al, Mg Stand. Tol.
design stage. 0.025
Cu Stand. Tol.
Zn Stand. Tol.
Tolerance in + Inches

0.02 Al, Mg Precis. Tol.

Cu Precis. Tol.
Zn Precis. Tol.
0.015

0.01

0.005

0
10 (64.50) 20 (129.0) 50 (322.6) 100 (645.2) 200 (1290) 300 (1935)
Projected Area in Inches Square (cm sq)

4-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-3-21
STANDARD
TOLERANCES

8 Moving Die Components (MDC): Standard Tolerances The values shown represent
Standard Tolerances, or
normal die casting produc-
Moving Die Components Tolerance can affect final part tion practice at the most
performance similar to Parting Line Tolerance. When the economical level. For
greater casting accuracy
core is fully inserted into the die, the minimum tolerance PL Core
Slide see Precision Tolerances
is zero. As excess material and pressure are exerted in the for this characteristic on
die, the core can slide out creating an oversized condition. the facing page. Be sure to
also address the procedures
A MDC Tolerance has been developed to ensure minimal E3E1 referred to in Section 7,
impact on form, fit and function by specifying limits to “Quality Assurance,” sub-
the oversize condition. *GD&T is required for radii and chamfers section 3, 4 and 5.
Similar to Parting Line Tolerance, MDC Standard **All corners should have radii or chamfers
Tolerance is a function of the Moving Die Component ***Draft should be added to any surface
(MDC) Tolerance plus Linear Tolerance. Linear parallel to die/tool movement Die Shift:
Tolerance is calculated based on the length of movement
Parting line die shift,
of the core slide along dimension “E3 E1”. Table S-4-1 unlike parting line
is used to determine Linear Tolerance. The linear dimension is not the entire length of “E3 E1” separation and moving die
but is only the length of the core slide from where the core slide first engages the die to its full component tolerances, is a
insertion position. Linear dimension is normally perpendicular to the Projected Area.
While moving die components have a natural tendency to only add material, there are some
left/right relationship with
possible ± consequences.
It can shift in four direc-
4
situations that can have the opposite effect on the part. For example, long die components can tions, based on a combina-
grow thermally larger than typically anticipated. Heavy die components may sag slightly or tion of part features, die
construction and operation
twist. Typically, these changes can be controlled with shutting die components off against each factors. It can occur at
other. In some cases, this may not be an option. These potential sources of dimensional varia- any time and its tolerance
tion should be discussed early in the process to expand tolerances, modify the datum structure, consequences should be
or modify the casting/die design to minimize issues. discussed with the die
caster at the design stage
Projected Area is the area of the core head that faces the molten material. MDC Tolerance for to minimize any impact on
moving die components is determined from table S-4-3. The open area (cavity) on the end view of the the final die casting.
part in figure 4-1A at the beginning of this section shows the projected area. Projected Area Toler-
ance plus Linear Tolerance provide MDC Standard Tolerance for the volume of the part. Note that Notes:
the tolerances in the table apply to a single casting regardless of the number of cavities. All values for part dimen-
Example: An aluminum casting has 75 in 2 (483.9 cm 2) of Projected Area calculated from the sions which run across the
core slide head facing the molten material. From table S-4-3, MDC Tolerance is +0.024. This die parting line are stated
as a “plus” tolerance only.
is combined with the length of the core slide Linear Tolerance from table S-4-1 to obtain the The die casting die at a die
MDC Standard Tolerance. The total core slide length of 5.00 in. (127 mm) is measured from closed position creates the
where the core engages the part to full insertion in the plane of dimension “E3 E1” to determine bottom of the tolerance
range, i.e., 0.000 (zero).
Linear Tolerance length. From table S-4-1, the Linear Tolerance is ±0.010 for the first inch and Due to the nature of the
±0.001 for each of the four additional inches. die casting process, dies
The Linear Tolerance of ±0.014 inches is combined with the MDC Tolerance of +0.024 to can separate imperceptibly
at the parting line and
yield a MDC Standard Tolerance of +0.038/-0.014 in. create only a larger, or
MDC Metric Standard Tolerance is +0.96/-0.35 mm = (±0.35 mm) + (+0.61 mm) on dimen- “plus” side, tolerance.
sions formed by moving die components.

Table S-4-3 MDC Tolerances (Standard) — Added to Linear Tolerances

Projected Area of Die Casting Die Casting Alloys (Tolerances shown are "plus" values only)
inches2 (cm2) Zinc Aluminum Magnesium Copper

up to 10 in2 +0.006 +0.008 +0.008 +0.012

(64.5 cm2) (+0.15 mm) (+0.20 mm) (+0.20 mm) (+0.305 mm)

11 in2 to 20 in2 +0.009 +0.013 +0.013

(71.0 cm2 to 129.0 cm2) (+0.23 mm) (+0.33 mm) (+0.33 mm)

21 in2 to 50 in2 +0.013 +0.019 +0.019

(135.5 cm2 to 322.6 cm2) (+0.33 mm) (+0.48 mm) (+0.48 mm)
51 in2 to 100 in2 +0.019 +0.024 +0.024
(329.0 cm2 to 645.2 cm2) (+0.48 mm) (+0.61 mm) (+0.61 mm)
101 in2 to 200 in2 +0.026 +0.032 +0.032
(651.6 cm2 to 1290.3 cm2) (+0.66 mm) (+0.81 mm) (+0.81 mm)
201 in2 to 300 in2 +0.032 +0.040 +0.040
(1296.8 cm2 to 1935.5 cm2) (+0.81 mm) (+1.0 mm) (+1.0 mm)

For projected area of die casting over 300 in2 (1935.5 cm2), consult with your die caster.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-11
 NADCA Engineering & Design: Tolerancing
P-4-3-21
PRECISION
TOLERANCES
Precision Tolerance values
shown represent greater cast- Moving Die Components (MDC): Precision Tolerances
ing accuracy involving extra
precision in die construc- Precision Tolerances attainable on die cast dimensions such as “E3 E1” formed by a moving die
tion and/or special control
in production. They should component will be the linear tolerance from table P-4-1 plus the value shown in table P-4-3.
be specified only when and Linear Tolerance is the length of the core slide. Projected Area is the area of the head of the core
where necessary, since addi-
tional costs may be involved. slide facing the molten material. The value chosen from table P-4-3 depends on the Projected
Be sure to also address the Area of the portion of the die casting formed by the moving die component (MDC) perpendicu-
procedures referred to in Sec- lar to the direction of movement. Note that
tion 7, “Quality Assurance,”
sub-section 3, 4 and 5. tolerances shown are plus side only.
Example: An aluminum die casting has 75 in 2
(483.9 cm 2) of Projected Area calculated from
Methods for PL Core
Slide

the core slide head facing the molten material.

Improving From table P-4-3, MDC Tolerance is +0.018.
Precision:
E3E1
This is combined with the length of the core
slide Linear Tolerance from table P-4-1 to
1. By repeated sampling
and recutting of the
obtain the MDC Precision Tolerance.
die casting tool, The total core slide length of 5.00 in. (127 mm) is measured from where the core engages the part to
along with production full insertion in the plane of dimension “E3 E1” to determine Linear Tolerance length from table P-4-1,
capability studies, even
closer dimensions can the Linear Tolerance is ±0.002 for the first inch and ±0.001 for each of the four additional inches. The
be held—at additional Linear Tolerance of ±0.006 inches is combined with the MDC Tolerance of +0.018 to yield a MDC
sampling or other costs.
Precision Tolerance of +0.024/-0.006 in.
2. The die casting process
may cause variations MDC Metric Precision Tolerance is +0.607/-0.15 mm = (±0.15 mm) +(+0.457 mm) on dimen-
to occur in parting sions formed by MDC.
line separation. Thus,
tolerances for dimen- Table P-4-3 MDC Tolerances (Precision) — Added to Linear Tolerances
sions that fall across the
parting line on any given Projected Area of Die Casting Die Casting Alloys (Tolerances shown are "plus" values only)
part should be checked inches2 (cm2) Zinc Aluminum Magnesium Copper
in multiple locations,
i.e., at four corners and up to 10 in2 +0.005 +0.006 +0.005 +0.010
on the center line. (64.5 cm2) (+0.127 mm) (+0.152 mm) (+0.127 mm) (+0.254 mm)

11 in2 to 20 in2 +0.007 +0.010 +0.007

(71.0 cm2 to 129.0 cm2) (+0.178 mm) (+0.254 mm) (+0.178 mm)

21 in2 to 50 in2 +0.010 +0.014 +0.010

(135.5 cm2 to 322.6 cm2) (+0.254 mm) (+0.356 mm) (+0.254 mm)
51 in2 to 100 in2 +0.014 +0.018 +0.014
(329.0 cm2 to 645.2 cm2) (+0.356 mm) (+0.457 mm) (+0.356 mm)
101 in2 to 200 in2 +0.019 +0.024 +0.019
(651.6 cm2 to 1290.3 cm2) (+0.483 mm) (+0.61 mm) (+0.483 mm)
201 in2 to 300 in2 +0.024 +0.030 +0.024
(1296.8 cm2 to 1935.5 cm2) (+0.61 mm) (+0.762 mm) (+0.61 mm)

For projected area of die casting over 300 in2 (1935.5 cm2), consult with your die caster.
Moving Die Tolerance
0.045
Al, Mg Stand. Tol.
0.04
Cu Stand. Tol.
Tolerance in + Inches

0.035 Zn Stand. Tol.

0.03 Al Precis. Tol.
Cu Precis. Tol.
0.025
Mg, Zn Precis. Tol.
0.02
0.015
0.01
0.005
0
10 20 50 100 200 300
(64.5) (129.0) (322.6) (645.2) (1290.) (1935.)
Projected Area in Inches Square (cm sq)

4-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S/P-4-4-21
STANDARD/PRECISION
TOLERANCES
Standard Tolerances shown
9 Angularity Tolerances (Plane surfaces): Standard & Precision Tolerances represent normal die casting
production practice at the
most economical level.
Angularity refers to the angular departure from the designed relationship between elements of Precision Tolerance values
the die casting. Angularity includes, but is not limited to, flatness, parallelism and perpendicu- shown represent greater
larity. The angular accuracy of a die casting is affected by numerous factors including size of the casting accuracy involv-
ing extra precision in die
die casting, the strength and rigidity of the die casting and die parts under conditions of high construction and/or special
heat and pressure, position of moving die components, and distortion during handling of the die control in production. They
should be specified only
casting. Angularity is not a stand alone tolerance. Angularity Tolerance is added to other part when and where necessary,
feature tolerances. For example, if determining tolerance for angular features at the Parting Line, since additional costs may be
Parting Line Tolerance and Angularity Tolerance would be added to yield total part tolerance. involved.
Angularity is calculated from the following tables based on the surface length that is impacted
by angularity and where the surface is located.
There are four tables for calculating Standard and Precision Angularity Tolerance.
• Table S/P-4-4 provides Angularity Tolerance for features in the same die half.
• Table S/P-4-4B provides Angularity Tolerance for features that cross the parting line.
• Table S/P-4-4C provides Angularity Tolerance for MDC features that are in the same die half.
• Table S/P-4-4D provides Angularity Tolerance for multiple MDC features or MDC features 4
that cross the parting line. The more MDCs involved, the more tolerance is necessary hence
multiple tables.
To extend die life a profile tolerance should be utilized when possible.

Applicability of Standard
This standard may be applied to plane surfaces of die castings for all alloys. Its tolerances are to
be considered in addition to those provided by other standards.

Angularity Tolerances - All Alloys

Tolerances required vary with the length of the surface of the die casting and the relative
location of these surfaces in the casting die.

Type Surfaces 3” Each 1” (25.4

(76.2 mm) or mm) over 3”
less (76.2 mm) SURFACE B DATUM A
Standard .005 (.13 mm) .001 (.025 mm)
Precision .003 (.08 mm) .001 (.025 mm)

Fixed Angularity Tolerance Same Die Half

0.016

0.014 Standard Tol.

Precision Tol.
Tolerance in Inches

0.012

0.01

0.008

0.006

0.004

0.002

0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Surface in Inches (mm)

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-13
 NADCA Engineering & Design: Tolerancing
S/P-4-4-21
STANDARD/PRECISION
TOLERANCES
Precision Tolerance values
shown represent greater cast-
Angularity Tolerances (Plane surfaces): Standard & Precision Tolerances
ing accuracy involving extra
precision in die construc-
tion and/or special control Same Die Half
in production. They should Example: Standard Tolerances — Surface -B- and the datum plane -A- are formed by the same die
be specified only when and
where necessary, since addi- half. If surface -B- is 5” (127 mm) long it will be parallel to the datum plane -A- within .007 (.18 mm).
tional costs may be involved. [.005 (.13 mm) for the first 3” (76.2 mm) and .002 (.05 mm) for the additional length.]

Example: Precision Tolerances — Surface -B- and the datum plane -A- are formed by the same die
Methods for half. If surface -B- is 5” (127 mm) long it will be parallel to the datum plane -A- within .005 (.13 mm).
[.003 (.08 mm) for the first 3” (76.2 mm) and .002 (.05 mm) for the additional length.]
Improving
Precision: Across Parting Line
Example: For Standard Tolerances — Surface -B- and the datum plane -A- are formed in opposite
1. By repeated sampling
and recutting of the
die sections. If surface -B- is 7” (177.8 mm) long it will be parallel to the datum plane -A- within
die casting tool, .014 (.36 mm).
along with production
capability studies, even
closer dimensions can [.008 (.20 mm) for the first 3” (76.2 mm) and .006 (.15 mm) for the additional length.]
be held—at additional
sampling or other costs.
2. The die casting process
may cause variations
Example: For Precision Tolerances — Surface -B- and the datum plane -A- are formed in opposite
to occur in parting die sections. If surface -B- is 7” (177.8 mm) long it will be parallel to the datum plane -A- within
line separation. Thus, .009 (.23 mm).
tolerances for dimen-
sions that fall across the
parting line on any given
part should be checked [.005(.13 mm) for the first 3” (76.2 mm) and .004 (.10 mm) for the additional length.]
in multiple locations,
i.e., at four corners and
on the center line.
3.

Type Surfaces 3” Each 1” (25.4 SURFACE B

(76.2 mm) or mm) over 3”
less (76.2 mm) DATUM A
Standard .008 (.20 mm) .0015 (.038
mm)
Precision .005 (.13 mm) .001 (.025 mm)

Fixed Angularity Tolerance Across PL

0.025
Standard Tol.
0.02 Precision Tol.
Tolerance in Inches

0.015

0.01

0.005

0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Surface in Inches (mm)

4-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S/P-4-4-21
STANDARD/PRECISION
TOLERANCES
Standard Tolerances shown
Angularity Tolerances (Plane surfaces): Standard & Precision Tolerances represent normal die casting
production practice at the
most economical level.
Example: For Standard Tolerances — Surface -B- is formed by a moving die member in the same
die section as datum plane -A-. If surface -B- is 5” (127 mm) long it will be perpendicular to the Precision Tolerance values
shown represent greater
datum plane -A- within .011 (.28 mm). casting accuracy involv-
ing extra precision in die
construction and/or special
[.008 (.20 mm) for the first 3” (76.2 mm) and .003 (.08 mm) for the additional length.] control in production. They
should be specified only
when and where necessary,
since additional costs may
Example: For Precision Tolerances — Surface -B- and the datum plane -A- are formed in opposite be involved.
die sections. If surface -B- is 7” (177.8 mm) long it will be parallel to the datum plane -A- within
.009 (.23 mm).

[.005(.13 mm) for the first 3” (76.2 mm) and .004 (.10 mm) for the additional length.]

Type Surfaces 3” Each 1” (25.4

(76.2 mm) or mm) over 3” SURFACE B
less (76.2 mm)
Standard .008 (.20 mm) .0015 (.038
DATUM A
mm)
Precision .005 (.13 mm) .001 (.025 mm)

MDC Angularity Tolerance Same Die Half

0.025
Standard Tol.
0.02 Precision Tol.
Tolerance in Inches

0.015

0.01

0.005

0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Surface in Inches (mm)

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-15
 NADCA Engineering & Design: Tolerancing
S/P-4-4-21
STANDARD/PRECISION
TOLERANCES
Standard Tolerances shown
represent normal die casting Angularity Tolerances (Plane surfaces): Standard & Precision Tolerances
production practice at the
most economical level.
Example: For Standard Tolerances — Surface -B- is formed by a moving die member and the
Precision Tolerance values
shown represent greater
datum plane -A- is formed by the opposite die section. If surface -B- is 5” (127 mm) long it will be
casting accuracy involv- perpendicular to the datum plane -A- within .017 (.43 mm). [.011 (.28 mm) for the first 3” (76.2
ing extra precision in die mm) and .006 (.15 mm) for the additional length.]
construction and/or special
control in production. They
should be specified only
when and where necessary, Surfaces -B- and -C- are formed by two moving die members. If surface -B- is used as the datum
since additional costs may be plane and surface -B- is 5” (127 mm) long, surface -C- will be parallel to surface -B- within .017 (.43
involved.
mm).

[.011 (.28 mm) for the first 3” (76.2 mm) and .006 (.15 mm) for the additional length.]

Example: For Precision Tolerances — Surface -B- is formed by a moving die member and the
datum plane -A- is formed by the opposite die section. If surface -B- is 5” (127 mm) long it will be
perpendicular to the datum plane -A- within .012 (.30 mm). [.008 (.20 mm) for the first 3” (76.2
mm) and .004 (.10 mm) for the additional length.]

Surfaces -B- and -C- are formed by two moving die members. If surface -B- is used as the datum
plane and surface -B- is 5” (127 mm) long, surface -C- will be parallel to surface -B- within .012 (.30
mm).

[.008 (.20 mm) for the first 3” (76.2 mm) and .004 (.10 mm) for the additional length.]

Type Surfaces 3” Each 1” (25.4 DATUM A

(76.2 mm) or mm) over 3”
less (76.2 mm)
SURFACE B SURFACE C
Standard .011 (.28 mm) .003 (.076 mm)
Precision .008 (.20 mm) .002 (.05 mm)

MDC Angularity Tolerance Across Parting Line

0.04

0.035 Standard Tol.

Precision Tol.
0.03
Tolerance in Inches

0.025

0.02

0.015

0.01

0.005

0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Linear Surface in Inches (mm)

4-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-5-21
STANDARD
TOLERANCES
Concentricity is defined as
10 Concentricity Tolerances: Varying Degrees of Standard Tolerance a feature having a common
center and is usually round,
The concentricity of cylindrical surfaces is affected by the design of the die casting. Factors, such circular or oval. Half the
diameter is the center of the
as casting size, wall thickness, shape, and complexity each have an effect on the concentricity of feature.
the measured surface. The tolerances shown below best apply to castings that are designed with
Standard and Precision
uniformity of shape and wall thickness. Tolerance are not specified
It should be noted that concentricity does not necessarily denote circularity (roundness). Part for Concentricity Tolerance
features can be considered concentric and still demonstrate an out of roundness condition. See section since tolerance is deter-
mined from diameter.
5.11, Runout vs. Concentricity, in Geometric Dimensioning & Tolerancing for further explanation.
Concentricity Tolerance is added to other tolerances to determine maximum tolerance for the As noted in the Concentric-
ity Tolerance description,
feature. For example, a concentric part that may cross the parting line, the tolerance would be concentricity does not
the Concentricity Tolerance added to Parting Line Tolerance to give overall part tolerance. Note denote roundness. The fea-
that the tolerances in the table apply to a single casting regardless of the number of cavities. ture may be oval and still
be concentric. Therefore
tolerance precision may be
One Die Section variable depending where
diameter is measured.
Concentricity Tolerance in a fixed relationship in one die section is calculated by selecting the
largest feature diameter, (Diameter A ) and calculating the tolerance from Table S-4-5A using
If minimum diameter is
chosen, the calculated toler-
4
the chosen diameter. See information in the side column regarding selecting diameters for oval ance from the table will
be less indicating a higher
features. Selected diameter directly impacts degree of precision. degree of precision.
If maximum diameter is
Example: Tolerance in One Die Section — An oval feature has a minimum diameter of 7 inches chosen, then calculated
and a maximum diameter of 8 inches identified by the largest oval in the drawing below. This feature tolerance will be more indi-
must fit into a hole with a high degree of precision. The minimum diameter (Diameter A) is chosen cating a more “standard”
degree of precision.
to give the highest degree of precision. From Table S-4-5A, the basic tolerance for the first 3 inches
is 0.008 inches Diameters chosen between
(0.20 mm). 0.002 minimum and maximum
Fixed Concentricity Same Die Half will determine varying
inches (0.05 mm) degrees of precision.
0.03
Largest Diameter A
is added for each
0.025 of the additional
Tolerance in Inches

0.02
4 inches to yield
a total Concen-
0.015 tricity Tolerance
0.01 of +0.016 inches
(+0.40 mm) for
0.005
the 7” diameter.
0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Largest Diameter in Inches (mm)

Table S-4-5A: Concentricity Tolerance - Same Die Half (Add to other tolerances)
T able S- 4A- 5 Co n cen t ricit y T oler an c es

Surfaces in Fixed Relationship in

One Die Section
Diameter of Largest Tolerance (T.I.R.)
PL
A
Diameter (A) inches (mm)
A B

B Basic Tolerance up to 3”
(76.2mm) .008 (.20 mm)

Additional Tolerance for each

additional inch (25.4 mm) over +.002 (.05 mm)
3” (76.2mm)

Surfaces formed by Opposite

4 / 2021 Halves of
NADCA Standards for High Integrity and Structural Die Casting Process / Section 4-17
Die (single cavity)
 NADCA Engineering & Design: Tolerancing
P-4-5-21
STANDARD
TOLERANCES
Concentricity is defined as
a feature having a common
Concentricity Tolerances: Varying Degrees of Standard Tolerance
center and is usually round,
circular or oval. Half the
diameter is the center of the
feature. Opposite Die Halves
Standard and Precision When concentric features are in opposite die halves, the area of the cavity at the parting line
Tolerance are not specified determines Concentricity Tolerance. If two concentric features meet at the parting line, it is the
for Concentricity Tolerance
since tolerance is determined area of the larger feature that determines Concentricity Tolerance from table S-4-5B. See the
from calculated area. side column for determining the area of a concentric feature. As noted in the side column, degree
As noted in the Concentric- of precision is determined from the calculated area when crossing the parting line.
ity Tolerance description, If there is a cavity at the parting line between concentric features that are located in opposite
concentricity does not denote die halves such as area C on the figure below, area of the cavity determines Concentricity
roundness. The feature may
be oval and still be concen- Tolerance from table S-4-5B.
tric. Concentricity Tolerance Total part tolerance is the combination of Concentricity Tolerance plus other feature
precision is determined from
chosen area and how the area tolerances for the part.
is calculated.
Example: Tolerance in One Die Section — An oval feature has a minimum diameter of 6 inches and a
maximum diameter of 8 inches identified as Diameter A. Diameter B is 5 inches. However, the area of
Concentric Area cavity C is 9 by 9 inches. If concentric features meet at the parting line through the squared area C, Con-
Calculation centricity Tolerance is determined from table S-4-5B by the 9 by 9 area which is 81 inches square. From
table S-4-5B the Concentricity Tolerance is +.012 inches (+.30 mm).
Round Features are those If concentric features meet at the parting line directly, the area of the larger oval is used to determine
with equal diameter
(D) regardless of where the Concentricity Tolerance from table S-4-5B. For example, if the minimum diameter is 6 inches and
measured. Their area is the maximum diameter is 8 inches, the average diameter is 7 inches. Using the Concentricity Area
calculated by: Calculation
(3.14) x [(1/2 D)2]
formula in the
side column, Concentricity Tolerance In Opposite Die Halves
Oval Feature areas are the area is 0.025
determined by averaging T able S- 4A- 5 Co n cen t ricit y T oler
determined anTol.
Conc. c esAcross PL
the minimum and maximum
diameters and then using to be 38.5 0.02
Tolerance in Inches

the same formula as that for inches square Surfaces in Fixed Relationship in
Round Features. therefore the 0.015
One Die Section
Concentricity
Tolerance is
0.01
Diameter of Largest Tolerance (T.I.R.)
PL
+.008 inches A 0.005
Diameter (A) inches (mm)
(+.20 mm).
B Basic Tolerance up to 3”
0
(76.2mm) .008 (.20 mm)
50 (323) 100 (645) 200 (1290) 300 (1936)
Projected Area in Inches Square (cm sq)
Additional Tolerance for each
additional inch (25.4 mm) over +.002 (.05 mm)
Table S-4-5B: Concentricity Tolerance - Opposite Die Halves (Add to other tolerances)
3” (76.2mm)

Surfaces formed by Opposite Halves of

Die (single cavity)

Projected Area (C) of Additional Tolerance

9 Inches
A casting inches (mm)
2
A B PL Up to 50 in
+ .008 (.20 mm)
9 Inches

2
B (323 cm )
2 2
51 in to 100 in
2 2 + .012 (.30 mm)
C - Die Cavity (329 cm to 645 cm )
C 2 2
101 in to 200 in
2 2 + .016 (.41 mm)
(652 cm to 1290 cm )
2 2
201 in to 300 in
2 2 + .022 (.56 mm)
(1297 cm to 1936 cm )

4-18 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-6-21
STANDARD
TOLERANCES
Parting Line Shift Tolerances
Parting Line Shift: Standard Tolerance are specified as standard
tolerances, only. If a higher
Parting line shift or die shift is a dimensional variation resulting from mismatch between the degree of precision is
required, the caster should be
two die halves. The shift is a left/right type relationship that can occur in any direction parallel consulted for possible steps
to the parting line of the two die halves. It has consequences to dimensions unlike parting line that can be taken.
separation and moving die component tolerances. Parting line shift will influence dimensions Parting Line Shift Tolerance
that are measured across the parting line including concentricity of features formed by opposite is only specified in Standard
die halves, and datum structures with datums in opposite die halves. Parting line shift com- Tolerance because this is
the lowest limit to meet the
pounds the affects of other tolerances measured across the parting line plane. Parting line shift requirements of form, fit and
can cause a part not to meet the requirements of form, fit and function. function at the most eco-
nomical value. Parting line
Dies are designed and built with alignment systems to minimize parting line shift. However, variation has a compounding
effectiveness of alignment systems in minimizing parting line shift will depend on temperature affect on feature tolerances
variations, die construction, type of die and wear. across the parting line.
Variations in temperature between the two die halves of the die occur during the die’s run.
With die steel changing size with temperature variation, the two die halves will change size
with respect to each other. To accommodate these changes in size, the alignment systems
are designed with clearance to eliminate binding during opening and closing of the die. This 4
clearance is necessary for the operation of the die but will allow a certain amount of parting
line shift. One side of the die may be heated or cooled to compensate for temperature variation
between die halves. One method to compensate for temperature variation is in the design and
gating of the die. Another method is to apply additional die lube between shots to cool the
hotter die half. Minimizing temperature variation between die halves allows for a more precise
alignment system which will limit temperature induced parting line shift.
Moveable components (slides) within a die can also lead to parting line shift. Mechanical locks
used to hold the slide in place during the injection of the metal can introduce a force that induces
a parting line shift in the direction of the pull of the slide.
The type of die will also affect parting line shift. Due to their design for inter-changeability, unit
dies will inherently experience greater parting line shift than full size dies. If parting line shift is
deemed critical during part design, a full size die should be considered rather than a unit die.
Steps can be taken during the part design stage to minimize the impact of parting line shift.
Datum structures should be set with all of the datum features in one half of the die. If this is
not possible, additional tolerance may need to be added (see Geometric Dimensioning, Section
5). Another consideration during part design is to adjust parting lines so those features where
mismatch is critical are cast in one half of the die.
Steps can also be taken during the die design to minimize parting line shift. Interlocks and
guide blocks can be added to dies to improve alignment, but result in a higher maintenance tool.
Placement of the cavities in the die can also be used to minimize the effect of mismatch between
the two die halves.
Die wear and alignment system wear may impact parting line shift. As components wear,
there is increasing lateral movement that will directly impact parting line shift. The method for
decreasing wear induced parting line shift is to minimize moving parts when designing a die
system, provide good cooling and lubrication, and have a good preventive maintenance program.
It is important to note that parting line shift can occur at any time and its tolerance conse-
quences should be discussed with the die caster at the design stage to minimize its impact on the
final die casting.
There are two components to calculate the affect of parting line shift on a part. The first
component is to determine Linear Tolerance. Linear Tolerance is obtained from table S/P-4-1
which was discussed earlier in this section. The second component is to determine Parting Line
Shift Tolerance. Cavity area at the parting line is used to determine Projected Area Tolerance
from table S-4-6.
Parting Line Shift Tolerance is added to the Linear Tolerance to obtain the volumetric affect
of total Parting Line Shift Tolerance on the part.
Parting Line Shift Tolerance is added to other feature tolerances to determine overall part tolerance.
Note that the tolerances in the table apply to a single casting regardless of the number of cavities.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-19
 NADCA Engineering & Design: Tolerancing
S-4-6-21
STANDARD
TOLERANCES

Parting Line Shift: Standard Tolerance

Example:
Parting Line
Shift Tolerance
The cavity area at
the parting line is
75 inches squared.
From Table S-4-6,
the Projected Area
Parting Line Shift
Tolerance is ± 0.006
(±0,152 mm). This is
added to the Linear
Tolerance from table Table S-4-6: Parting Line Shift Tolerance (Excluding unit dies)
S/P-4-1. Table SP-4-6 Parting Line Shift Tolerance (excluding unit dies)
Projected Area of Die Casting Additional Tolerance
Note: The table inches 2 (cm 2) inches (mm)
represents a step func- up to 50 in 2 ±.004
tion for additional (322.6 cm 2) (±.102 mm)
tolerance based on
51 in 2 to 100 in 2 ±.006
projected area, whereas
(329.0 cm 2 to 645.2 cm 2) (±.152 mm)
the graph represents a
linear interpolation 101 in 2 to 200 in 2 ±.008
(651.6 cm 2 to 1290.3 cm 2) (±.203 mm)
between points. A
die caster should be 201 in 2 to 300 in 2 ±.011
contacted to discuss (1296.8 cm 2 to 1935.5 cm 2) (±.279 mm)
appropriate tolerance 301 in 2 to 500 in 2 ±.016
for a specific part. (1941.9 cm 2 to 3225.8 cm 2) (±.406 mm)
501 in 2 to 800 in 2 ±.020
(3232.3 cm 2 to 5161.3 cm 2) (±.508 mm)
801 in 2 to 1200 in 2 ±.025
(5167.7 cm 2 to 7741.9 cm 2) (±.635 mm)

Parting Line Shift Tolerance

0.03

PL Shift Tolerance
0.025
Tolerance in Inches

0.02

0.015

0.01

0.005

0
50 100 200 300 500 800 1200
(322.6) (645.2) (1290.3) (1935.5) (3225.8) (5161.3) (7741.9)
Projected Area in Inches Square (cm sq)

4-20 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S/P-4-7-21
STANDARD/PRECISION
TOLERANCES

Draft Requirements: Standard Tolerances

Draft is the amount of taper or slope given to cores or other parts of the die cavity to permit easy
ejection of the casting.
All die cast surfaces which are normally perpendicular to the parting line of the die require
draft (taper) for proper ejection of the casting from the die. Draft is expressed as an angle of the
casting surface relative to a line perpendicular to the parting line (See dimension A in the “Draft
Example”). This draft requirement, expressed as an angle, does not need to be constant for all
walls. It can vary with the type of wall or surface specified, the depth of the surface and the alloy
selected.
Draft is recommended to be between 1-2°, but can vary depending on a number of factors. A
die caster and designer should discuss draft angles to ensure that the die casting will meet the
needs of the application, while still being manufactured economically.
Factors that can affect the draft angle required on a surface are: depth of the feature, metal
being cast, as-cast elongation of the casting, inside versus outside wall surface.
• Features with more depth (see dimension D in the “Draft Example”) will require less draft angle
than shallower features. 4
• Aluminum die castings will require more draft angle than zinc die castings. Aluminum, magne-
sium, and copper castings will be similar in the amount of draft angle required.
• Structural aluminum die castings (which have higher as-cast elongation) may not require as
much draft angle as a conventional aluminum die castings (which have lower as-cast elongation)
• Twice as much draft is recommended for inside walls or surfaces as for outside walls or surfaces.
This provision is required because as the alloy solidifies it shrinks onto the die features that form
inside surfaces (usually located in the ejector half) and away from features that form outside
surfaces (usually in the cover half).
Note that the recommended draft angle does not apply to cast lettering, logotypes or engrav-
ing. Such elements must be examined individually as to style, size and depth desired.

Draft Example
The following examples shows how the depth and draft angle can affect the draft distance.

Draft Draft To achieve lesser draft than normal

Depth
Distance Angle production allows, discuss with the
(D)
(D) (A) die caster.
in. in. (mm) Degrees
(mm)
0.1 0.0035 2”
(2.54) (0.089)
1.0 0.26 1.5”
(25) (0.655)
5.0 0.0035 1”
(127) (0.089)

Drawing defines draft

dimensions for interior
and exterior surfaces
and total draft for holes
(draft is exaggerated for
illustration).

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-21
 NADCA Engineering & Design: Tolerancing
S/P-4-7-21
STANDARD/PRECISION
TOLERANCES
It is not common practice to specify draft separately for each feature. Draft is normally
specified by a general note with exceptions called out for individual features. The formula should
be used to establish general draft requirements with any exceptions identified.
For example, an aluminum casting with most features at least 1.0 in. deep can be covered with a
general note indicating 2° minimum draft on inside surfaces and 1° minimum on outside surfaces
(based on outside surfaces requiring half as much draft).

* For tapped holes cored with removable core pins for subsequent threading see page 4-28 through 4-31.

4-22 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-8-21
STANDARD
TOLERANCES

Flatness Requirements: Standard Tolerance The flatness values shown

here represent Standard
Tolerances, or normal cast-
Flatness defines surface condition not part thickness. See the flatness explanation on the opposite page. ing production practice at
the most economical level.
Standard Tolerance is calculated using the largest dimensions defining the area where the For greater casting accu-
tolerance is to be applied. If flatness is to be determined for a circular surface such as the top racy see Precision Toler-
ances for this characteristic
of a can, the largest dimension is the diameter of the can. If flatness is to be determined for a on the facing page.
rectangular area, the largest dimension is a diagonal.
For greater accuracy, see Precision Tolerances for flatness on the opposite page. Flatness is described in
detail in Section 5, Geo-
metric Dimensioning &
Example: Flatness Tolerance - Diagonal Tolerancing. Simply put,
Flatness Tolerance is the
For a part where the diagonal measures 10 inches (254 mm), the maximum Flatness Standard amount of allowable sur-
face variation between two
Tolerance from table S-4-8 is 0.008 inches (0.20 mm) for the first three inches (76.2 mm) plus parallel planes which define
0.003 inches (0.08 mm) for each of the additional seven inches for a total Flatness Standard the tolerance zone. See the
figures below.
Tolerance of 0.029 inches (0.76 mm).
Flatness of a continuous
Table P-4-8 Flatness Tolerances, As-Cast: All Alloys
plane surface on a casting
should be measured by a
method mutually agreed
4
Maximum Dimension Tolerance
of Die Cast Surface inches (mm) upon by the designer, die
caster and the customer
up to 3.00 in. 0.005 before the start of die
(76.20 mm) (0.13 mm) design.

Additional tolerance, 0.002

in. (25.4 mm) for each additional in. (25.4 mm) (0.05 mm) Note:
Flatness Example The maximum linear
dimension is the diameter
Flatness Example of a circular surface or the
diagonal of a rectangular
surface.

Flatness Design
Guidelines:
1. All draft on walls,
bosses and fins
surrounding and un-
derneath flat surfaces
should be standard
draft or greater.
2. Large bosses or cross
sections can cause
Explanation sinks and shrinkage
distortions and should
be avoided directly
Explanation beneath flat surfaces.
3. Changes in cross
section should be
gradual and well
filleted to avoid
stress and shrinkage
distortions.
4. Symmetry is important
to obtain flatness.
Lobes, legs, bosses
and variations in wall
height can all affect
flatness.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-23
 NADCA Engineering & Design: Tolerancing
P-4-8-21
PRECISION
TOLERANCES
Precision Tolerance values
for flatness shown represent Flatness Requirements: Precision Tolerance
greater casting accuracy
involving extra precision The values shown for Precision Tolerance for flatness represent greater casting accuracy involving
in die construction. They
should be specified only extra steps in die construction and additional controls in production. They should be specified
when and where necessary only when and where necessary since additional costs may be involved.
since additional cost may be
involved. Even closer tolerances may be held by working with the die caster to identify critical zones of
flatness. These areas may be amenable to special die construction to help maintain flatness.
Notes:
The maximum linear dimen- Flatness Explanation
sion is the diameter of a cir-
cular surface or the diagonal As noted in the explanation diagram, at the bottom of the page, flatness is independent of all
of a rectangular surface.
other tolerance features including thickness.
Part thickness has a nominal thickness of 0.300 ±0.010. Flatness Tolerance is 0.005. Therefore
Flatness Design at the high limit thickness the part surface flatness can be between 0.305 and 0.310. Nominal
Guidelines: thickness flatness can be between .2975 and .3025. Low limit thickness flatness can be between
0.290 and 0.295. Flatness can not range between 0.290 and 0.310. Using both high and low
1. All draft on walls, thickness in combination with flatness defeats the purpose for specifying flatness.
bosses and fins sur-
rounding and underneath
flat surfaces should be
standard draft or greater.
Example: Flatness Tolerance - Diagonal
2. Large bosses or cross For a part where the diagonal measures 10 inches (254 mm), the maximum Flatness Precision
sections can cause
sinks and shrinkage Tolerance from table P-4-8 is 0.005 inches (0.13 mm) for the first three inches (76.2 mm) plus
distortions and should be 0.002 inches (0.05 mm) for each of the additional seven inches for a total Flatness Standard
avoided directly beneath Tolerance of 0.019 inches (0.48 mm).
flat surfaces.
3. Changes in cross section Table P-4-8 Flatness Tolerances, As-Cast: All Alloys
should be gradual and
well filleted to avoid Maximum Dimension Tolerance
stress and shrinkage of Die Cast Surface inches (mm)
distortions.
4. Symmetry is important up to 3.00 in. 0.005
to obtain flatness. (76.20 mm) (0.13 mm)
Lobes, legs, bosses and
variations in wall height Additional tolerance, 0.002
can all affect flatness. in. (25.4 mm) for each additional in. (25.4 mm) (0.05 mm)

Flatness Tolerance
0.05

0.045 Standard Tolerance Zone

Precision Tolerance Zone
0.04
Tolerance in + Inches

0.035

0.03

0.025

0.02

0.015

0.01

0.005

0
3 4 5 6 7 8 9 10 11 12
(76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)

Explanation Tolerance Zone in Inches (mm)

.005 TOL ZONE .005 TOL ZONE .005 TOL ZONE

.310 .300 .290

PART AT HIGH PART AT PART AT LOW

SIZE LIMIT NOMINAL SIZE SIZE LIMIT

4-24 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

Design Recommendations: Cored Holes As-Cast

Cored holes in die castings can be categorized according to their function. There are three
major classifications.
• Metal savers
• Clearance holes
• Function/locating holes
Each of these functions implies a level of precision. Metal savers require the least precision;
function/locating holes require the greatest precision. Leaving clearance holes in-between.
Specifications for cored holes are the combination of form, size and location dimensions and
tolerances required to define the hole or opening.

Metal Savers
Metal savers are cored features, round or irregular, blind or through the casting, whose primary
purpose is to eliminate or minimize the use of raw material (metal/alloy). The design objective
of the metal saver is to reduce material consumption, while maintaining uniform wall thickness,
good metal flow characteristics, good die life characteristics with minimal tool maintenance.
4
In the design of ribs and small metal savers the designer needs to be aware to avoid creating
“small” steel conditions in the tool that can be detrimental to tool life.

Design recommendation:
1. Wall thickness
Design for uniform wall thickness around metal savers. Try to maintain wall thickness within ±10%
of the most typical wall section.
2. Draft
Use draft constant per NADCA S-4-7 for inside walls. Keep walls as parallel as practical.
3. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA guidelines
G-6-2. Consider 0.06 inch radius (1.5 mm radius) as a minimum. A generous radius at transitions
and section changes will promote efficient metal flow during cavity filling.

Clearance Holes
Clearance holes are cored holes, round or irregular, blind or through the casting, whose primary
purpose is to provide clearance for features and components. Clearance implies that location of
the feature is important.

Design recommendation:
1. Tolerance
Dimensions locating the cored hole should be per NADCA Standard tolerances; S-4-1 Linear
Dimension, S-4-2 Parting Line Dimensions and S-4-3 Moving Die Components.
2. Wall thickness
Design for uniform wall thickness around clearance holes. Try to maintain wall thickness
within ±10% of the most typical wall section. If hole is a through hole, allowance should be
made for any trim edge per NADCA G-6-5, Commercial Trimming within 0.015 in. (0.4 mm).
3. Draft
Use draft constant per NADCA S-4-7 for inside walls. Keep walls as parallel as practical.
4. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA
guidelines G-6-2. Consider 0.06 inch radius (1.5 mm radius.) as a minimum. A generous
radius at transitions and section changes will promote efficient metal flow during cavity filling.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-25
 Engineering & Design: Tolerancing

For holes with less than a Functional/Locating Holes

0.25 inch diameter, wall
stock may be a minimum of Functional/locating holes are cored holes whose purpose is to provide for a functional purpose
one half the hole diam- such as threading, inserting and machining or location and alignment for mating parts or
eter. Unless wall thickness
is required for strength. secondary operations.
However, Ribbing Should be
applied first.
Design recommendation:
For holes with larger than a
0.25 inch diameter, the wall 1. Tolerance
stock shall be the nominal Dimensions locating the cored hole to be per NADCA Precision tolerances; P-4-1 Linear
wall thickness (subject to
part design). Dimension, P-4-2 Parting Line Dimensions and P-4-3 Moving Die Components.
These rules can be broken
2. Wall thickness
if the product requires more Design for uniform wall thickness around functional/locating holes. Try to maintain wall
strength. However, ribbing thickness within ±10% of the most typical wall section. If hole is a through hole, allowance
should be attempted first.
should be made for any trim edge per NADCA G-6-5, Commercial Trimming within 0.015
inch (0.4 mm) or if this is not acceptable, a mutually agreed upon requirement.
3. Draft
Use draft constant per NADCA P-4-7 for inside walls. Keep walls as parallel as practical.
4. Radii/fillets
Use as large a radius as possible, consistent with uniform wall thickness. Refer to NADCA
guidelines G-6-2. Consider 0.03 inch radius (0.8 mm radius.) as a minimum. A generous
radius at transitions and section changes will promote efficient metal flow during cavity filling.

Other Design Considerations

Hole depths

Diameter of Hole — Inches

1/8 5/32 3/16 1/4 3/8 1/2 5/8 3/4 1
Alloy Maximum Depth — Inches
Zinc 3/8 9/16 3/4 1 1-1/2 2 3-1/8 4-1/2 6
Aluminum 5/16 1/2 5/8 1 1-1/2 2 3-1/8 4-1/2 6
Magnesium 5/16 1/2 5/8 1 1-1/2 2 3-1/8 4-1/2 6
Copper 1/2 1 1-1/4 2 2-1/2 5

*Depths are recommended maximums and are not necessarily the limits for a specific die caster. Consult a
die caster to discuss their capabilities.

Note:
The depths shown are not applicable under conditions where small diameter cores are widely
spaced and, by design, are subject to full shrinkage stress.

Perpendicularity
See Section 5 pages 5-19 and 5-20 Orientations Tolerances.

4-26 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

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NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-27
 NADCA Engineering & Design: Tolerancing
S-4-9-21
STANDARD
TOLERANCES
The values shown represent
Standard Tolerances, or Cored Holes for Cut Threads: Standard Tolerances
normal casting production
practice at the most economi- Cored holes for cut threads are cast holes that require threads to be cut (tapped) into the metal.
cal level. For greater casting
accuracy see Precision Toler- The table below provides the dimensional
ances for the characteristic
X tolerances for diameter, depth and draft
on the facing page.
Y
Tip or for each specified thread type (Unified and
Spherical
Metric Series). When required, cored holes in
Radius
Optional Al, Mg, Zn and ZA may be tapped without
D1 D2 removing draft. This Standard Tolerance
recommendation is based on allowing 85%
of full thread depth at the bottom D2 (small
end) of the cored hole and 55% at the top D1
(large end) of the cored hole. A countersink or radius is also recommended at the top of the cored
hole. This provides relief for any displaced material and can also serve to strengthen the core.
Threads extend through the cored hole as by Y. X shows the actual hole depth. As with the
countersink at the top of the hole, the extra hole length provides relief for displaced material and
allows for full thread engagement. Tolerances below apply to all alloys.

Table S-4-9: Cored Holes for Cut Threads (Standard Tolerances) – Unified Series and Metric Series
Table S-4A-9 Cored Holes for Cut Threads (Standard Tolerances) — Unified Series and Metric Series
Unified Hole Diameter Thread Depth Hole Depth Metric Hole Diameter Thread Depth Hole Depth
Series/ D 1, Max. D 2, Min. Y, Max. X, Max. Series D 1, Max. D 2, Min. Y, Max. X, Max.
Class Thread
inches inches inches inches Size mm mm mm mm
6-32, UNC/2B, 3B 0.120 0.108 0.414 0.508 M3.5 X 0.6 3.168 2.923 7.88 9.68
6-40, UNF/2B 0.124 0.114 0.345 0.420 M4 X 0.7 3.608 3.331 9.00 11.10
8-32, UNC/2B 0.146 0.134 0.492 0.586 M5 X 0.8 4.549 4.239 11.25 13.65
8-36, UNF/2B 0.148 0.137 0.410 0.493 M6 X 1 5.430 5.055 13.50 16.50
10-24, UNC/2B 0.166 0.151 0.570 0.695 M8 X 1.25 7.281 6.825 18.00 21.75
10-32, UNF/2B 0.172 0.160 0.475 0.569 f M8 X 1 7.430 7.055 14.00 17.00
12-24, UNC/2B 0.192 0.177 0.648 0.773 M10 X 1.5 9.132 8.595 22.50 27.00
12-28, UNF/2B 0.196 0.182 0.540 0.647 f M10 X 0.75 9.578 9.285 10.00 12.25
1/4A-20, UNC/1B, 2B 0.221 0.203 0.750 0.900 f M10 X 1.25 9.281 8.825 20.00 23.75
1/4A-28, UNF/1B, 2B 0.230 0.216 0.500 0.607 M12 X 1.75 10.983 10.365 27.00 32.25
5/16-18, UNC/1B, 2B 0.280 0.260 0.781 0.948 f M12 X 1 11.430 11.055 15.00 18.00
5/16-24, UNF/1B, 2B 0.289 0.273 0.625 0.750 f M12 X 1.25 11.281 10.825 18.00 21.75
3/8-16, UNC/1B, 2B 0.339 0.316 0.938 1.125 M14 X 2 12.834 12.135 31.50 37.50
3/8-24, UNF/1B, 2B 0.351 0.336 0.656 0.781 fM14 X 1.5 13.132 12.595 24.50 29.00
7/16-14, UNC/1B, 2B 0.396 0.371 1.094 1.308 f M15 X 1 14.430 14.055 15.00 18.00
7/16-20, UNF/1B, 2B 0.409 0.390 0.766 0.916 M16 X 2 14.834 14.135 32.00 38.00
1/2-13, UNC/1B, 2B 0.455 0.428 1.250 1.481 f M16 X 1.5 15.132 14.595 24.00 28.50
1/2-20, UNF/1B, 2B 0.471 0.453 0.750 0.900 f M17 X 1 16.430 16.055 15.30 18.30
9/16-12, UNC/1B, 2B 0.514 0.485 1.406 1.656 f M18 X 1.5 17.132 16.595 24.30 28.80
9/16-18, UNF/1B, 2B 0.530 0.510 0.844 1.010 M20 X 2.5 18.537 17.675 40.00 47.50
5/8-11, UNC/1B, 2B 0.572 0.540 1.563 1.835 f M20 X 1 19.430 19.055 15.00 18.00
5/8-18, UNF/1B, 2B 0.593 0.573 0.781 0.948 f M20 X 1.5 19.132 18.595 25.00 29.50
3/4A-10, UNC/1B, 2B 0.691 0.657 1.688 1.988 f M22 X 1.5 21.132 20.595 25.30 29.80
3/4A-16, UNF/1B, 2B 0.714 0.691 0.938 1.125 M24 X 3 22.239 21.215 48.00 57.00
7/8- 9, UNC/1B, 2B 0.810 0.772 1.750 2.083 f M24 X 2 22.834 22.135 30.00 36.00
7/8-14, UNF/1B, 2B 0.833 0.808 1.094 1.308 f M25 X 1.5 24.132 23.595 25.00 29.50
1- 8, UNC/1B, 2B 0.927 0.884 2.000 2.375 f M27 X 2 25.834 25.135 33.75 39.75
1-12, UNF/1B. 2B 0.951 0.922 1.250 1.500 M30 X 3.5 27.941 26.754 60.00 70.50

f = Fine Pitch Series

4-28 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
P-4-9-21
PRECISION
TOLERANCES
The Precision Tolerance
Cored Holes for Cut Threads: Precision Tolerances values shown represent
greater casting accuracy
Cored holes for cut threads are cast holes that involving extra precision
X in die construction and/or
require threads to be cut (tapped) into the Tip or special control in production.
Y
metal. The table below provides the dimen- Spherical They should be specified
Radius only when and where neces-
sional tolerances for diameter, depth and draft sary, since additional cost
Optional
for each specified thread type (Unified and D1 D2 may be involved.
Metric Series). When required, cored holes in
Al, Mg, Zn and ZA may be tapped without
removing draft. This Precision Tolerance
recommendation is based on allowing 95% of full thread depth at the bottom D2 (small end) of
the cored hole and the maximum minor diameter at the top D1 (large end) of the cored hole. A
countersink or radius is also recommended at the top of the cored hole. This provides relief for any
displaced material and can also serve to strengthen the core.

4
Table P-4-9: Cored Holes for Cut Threads (Precision Tolerances) – Unified Series and Metric Series
Table P-4A-9 Cored Holes for Cut Threads (Precision Tolerances) — Unified Series and Metric Series
Unified Hole Diameter Thread Depth Hole Depth Metric Hole Diameter Thread Depth Hole Depth
Series/ D 1, Max. D 2, Min. Y, Max. X, Max. Series D 1, Max. D 2, Min. Y, Max. X, Max.
Class Thread
inches inches inches Size mm mm mm mm

0-80, UNF/2B, 3B (0.051) (0.047) (0.130) (0.163) M1.6 X 0.35 (1.32) (1.24) (2.40) (3.45)
1-64, UNC/2B, 3B (0.062) (0.057) (0.200) (0.250) M2 X 0.4 (1.68) (1.59) (3.00) (4.20)
1-72, UNF/2B, 3B (0.064) (0.059) (0.160) (0.200) M2.5 X 0.45 (2.14) (2.04) (3.75) (5.10)
2-56, UNC/2B, 3B (0.074) (0.068) (0.240) (0.300) M3 X 0.5 (2.60) (2.49) (4.50) (6.00)
2-64, UNF/2B, 3B (0.075) (0.070) (0.200) (0.250) M3.5 X 0.6 2.99 2.88 5.25 7.05
3-48, UNC/2B, 3B (0.085) (0.078) (0.280) (0.350) M4 X 0.7 3.42 3.28 6.00 8.10
3-56, UNF/2B, 3B (0.087) (0.081) (0.220) (0.275) M5 X 0.8 4.33 4.17 7.50 9.90
4A-40, UNC/2B, 3B (0.094) (0.086) (0.320) (0.400) M6 X 1 5.15 4.96 9.00 12.00
4A-48, UNF/2B, 3B (0.097) (0.091) (0.240) (0.300) M8 X 1.25 6.91 6.70 12.00 15.75
5-40, UNC/2B, 3B 0.106 0.099 0.280 0.350 f M8 X 1 7.15 6.96 12.00 15.00
5-44, UNF/2B, 3B 0.108 0.102 0.240 0.300 M10 X 1.5 8.68 8.44 15.00 19.50
6-32, UNC/2B, 3B 0.114 0.106 0.350 0.438 f M10 X 0.75 9.38 9.23 12.50 14.75
6-40, UNF/2B 0.119 0.112 0.270 0.338 M10 X 1.25 8.91 8.70 15.00 18.75
8-32, UNC/2B 0.139 0.132 0.290 0.363 M12 X 1.75 10.44 10.17 18.00 23.25
8-36, UNF/2B 0.142 0.135 0.260 0.325 f M12 X 1 11.15 10.96 15.00 18.00
10-24, UNC/2B 0.156 0.147 0.390 0.488 f M12 X 1.25 10.91 10.70 15.00 18.75
10-32, UNF/2B 0.164 0.158 0.240 0.300 M14 X 2 12.21 11.91 21.00 27.00
12-24, UNC/2B 0.181 0.173 0.340 0.425 f M14 X 1.5 12.68 12.44 21.00 25.50
12-28, UNF/2B 0.186 0.179 0.270 0.338 f M15 X 1 14.15 13.96 18.75 21.75
1/4A-20, UNC/1B, 2B 0.207 0.199 0.370 0.463 M16 X 2 14.21 13.91 28.00 34.00
1/4A-28, UNF/1B, 2B 0.220 0.213 0.270 0.338 f M16 X 1.5 14.68 14.44 24.00 28.50
5/16-18, UNC/1B, 2B 0.265 0.255 0.440 0.550 f M17 X 1 16.15 15.96 17.00 20.00
5/16-24, UNF/1B, 2B 0.277 0.270 0.310 0.388 f M18 X 1.5 16.68 16.44 22.50 27.00
3/8-16, UNC/1B, 2B 0.321 0.311 0.470 0.588 M20 X 2.5 17.74 17.38 30.00 37.50
3/8-24, UNF/1B, 2B 0.340 0.332 0.340 0.425 f M20 X 1 19.15 18.96 20.00 23.00
7/16-14, UNC/1B, 2B 0.376 0.364 0.570 0.713 f M20 X 1.5 18.68 18.44 20.00 24.50
7/16-20, UNF/1B, 2B 0.395 0.386 0.400 0.500 f M22 X 1.5 20.68 20.44 22.00 26.50
1/2-13, UNC/1B, 2B 0.434 0.421 0.640 0.800 M24 X 3 21.25 20.85 36.00 45.00
1/2-20, UNF/1B, 2B 0.457 0.449 0.370 0.463 f M24 X 2 22.21 21.91 30.00 36.00
9/16-12, UNC/1B, 2B 0.490 0.477 1.280 1.600 f M25 X 1.5 23.68 23.44 25.00 29.50
9/16-18, UNF/1B, 2B 0.515 0.505 0.880 1.100 f M27 X 2 25.21 24.91 27.00 33.00
5/8-11, UNC/1B, 2B 0.546 0.532 1.430 1.788 M30 X 3.5 26.71 26.31 37.50 48.00
5/8-18, UNF/1B, 2B 0.578 0.568 0.930 1.163
3/4A-10, UNC/1B, 2B 0.663 0.647 1.590 1.988 a Values in italics and parenthesis apply to zinc and magnesium only
3/4A-16, UNF/1B, 2B 0.696 0.686 0.950 1.188 b f = Fine Pitch Series
7/8- 9, UNC/1B, 2B 0.778 0.761 1.750 2.188
Note:
For both Unified and Metric Series, if hole size tolerances for D1 and D2 are
7/8-14, UNF/1B, 2B 0.814 0.802 1.200 1.500
required, in place of maximum and minimum values, the recommended
1- 8, UNC/1B, 2B 0.890 0.871 1.900 2.375
tolerance for D1 is -0.0005 in. (-0.015 mm) and for D2 is +0.0005 in. (+0.015
1-12, UNF/1B. 2B 0.928 0.914 1.340 1.675 mm). Accurate measurement of holes with these Precision Tolerances requires
measurement capability greater than what pin gages can measure.

Values in italics and parentheses are achievable but should be discussed with the die caster prior to finalization of a casting design.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-29
 NADCA Engineering & Design: Tolerancing
P-4-10-21
PRECISION
TOLERANCES
Cored holes for formed
threads are specified in die Cored Holes for Formed Threads: Precision Tolerances
castings as Precision Toler-
ances, because they require The Precision Tolerance recommendations for cored holes for formed threads, on the opposite
special control in production.
The specific diameter, depth page, are based on allowing 75% of full thread depth at the bottom D2 (small end) of the cored
and draft required will deter- hole and 50% at the top D1 (large end) of the cored hole. When required, cored holes in alumi-
mine the added cost.
num, zinc and magnesium may be tapped without removing draft.
Cold form taps displace material in an extrusion or swaging process. As a result, threads are
Note:
Tolerances for cored holes
stronger because the material is work hardened as a part of the process for forming threads.
for thread forming fasteners Because material is displaced, a countersink is recommended at the ends of through holes and at
(self tapping screws) should the entry of blind holes.
be provided by the manufac-
turer of the specific type of Tests indicate that thread height can be reduced to 60% without loss of strength, based on the
thread forming fastener to fact cold formed threads in die castings are stronger than conventional threads. However, the use
be used.
of 65% value is strongly recommended.
Since cored holes in castings must have draft (taper), the 65% thread height Y should be at a
depth that is an additional one-half of the required engagement length of the thread in the hole.
Blind holes should be cored deep enough to allow a four (4) thread lead at the bottom of the
hole. This will result in less burr around the hole and longer tool life. Hole sizes of #6 or less, or
metric M3 or less, are recommended for through holes only.
Cold form tapping is not recommended for holes with a wall thickness less than two-thirds
the nominal diameter of the thread.
The Precision Tolerance recommendation should be considered as a starting point with respect
to depth recommendations. There are many applications that do not require the percent of thread
listed here. If a lesser percent of thread can be permitted, this would, in turn, allow more draft
and a deeper hole. Amount and direction of required strength can be determined by testing.

4-30 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
P-4-10-21
PRECISION
TOLERANCES
The Precision Tolerance
Cored Holes for Formed Threads: Precision Tolerances values shown represent
greater casting accuracy
The tolerances below apply to AI, Mg, Zn and ZA die casting alloys, as footnoted. Note that, when involving extra precision in
construction and/or special
required, cored holes in aluminum, zinc, and magnesium may be tapped without removing draft. control in production. They
Guidelines are provided on the opposite page should be specified only
X when and where necessary,
Tip or regarding thread height, depth, and limitations since additional cost may
Y Spherical on wall thickness. be involved.
Radius
Optional
D1 D2

Table
TableP-4-10: Cored
P-4A-10 Holes
Cor for Formed
ed Holes Threads Thr
for Formed (Precision
eads (PreTolerances) – Unified
cision)— Unified Series
Series andandMetric
MetricSeries
Series
Unified Hole Diameter Thread Depth Hole Depth Metric Hole Diameter Thread Depth Hole Depth
Series D 1, Max. D 2, Min. Y, Max. X, Max. Series D 1, Max. D 2, Min Y, Max. X, Max.
Class
inches inches inches inches
Thread
Size mm mm mm mm 4
0-80, UNF/2B, 3B (0.0558) (0.0536) (0.090) (0.120) M1.6 X 0.35 (1.481) (1.422) (2.4) (3.2)
1-64, UNC/2B, 3B (0.0677) (0.0650) (0.110) (0.146) M2 X 0.4 (1.864) (1.796) (3.0) (4.0)
1-72, UNF/2B, 3B (0.0683) (0.0659) (0.110) (0.146) M2.5 X 0.45 (2.347) (2.271) (3.8) (5.0)
2-56, UNC/2B, 3B (0.0799) (0.0769) (0.129) (0.172) M3 X 0.5 (2.830) (2.745) (4.5) (6.0)
2-64, UNF/2B, 3B (0.0807) (0.0780) (0.129) (0.172) M3.5 X 0.6 3.296 3.194 7.0 10.5
3-48, UNC/2B, 3B (0.0919) (0.0884) (0.149) (0.198) M4 X 0.7 3.762 3.643 8.0 12.0
3-56, UNF/2B, 3B (0.0929) (0.0899) (0.149) (0.198) M5 X 0.8 4.728 4.592 10.0 15.0
4A-40, UNC/2B, 3B (0.1035) (0.0993) (0.168) (0.224) M6 X 1 5.660 5.490 12.0 18.0
4A-48, UNF/2B, 3B (0.1049) (0.1014) (0.168) (0.224) M8 X 1.25 7.575 7.363 16.0 24.0
5-40, UNC/2B, 3B (0.1165) (0.1123) (0.188) (0.250) f M8 X 1 7.660 7.490 16.0 24.0
5-44, UNF/2B, 3B (0.1173) (0.1134) (0.188) (0.250) M10 X 1.5 9.490 9.235 20.0 30.0
6-32, UNC/2B, 3B (0.1274) (0.1221) (0.207) (0.276) f M10 X 0.75 9.745 9.618 12.5 30.0
6-40, UNF/2B (0.1295) (0.1253) (0.207) (0.276) fM10 X 1.25 9.575 9.363 20.0 30.0
8-32, UNC/2B 0.153 0.148 0.328 0.492 M12 X 1.75 11.41 11.11 24.0 36.0
8-36, UNF/2B 0.155 0.150 0.328 0.492 f M12 X 1 11.66 11.49 18.0 36.0
10-24, UNC/2B 0.176 0.169 0.380 0.570 f M12 X 1.25 11.58 11.36 18.0 36.0
10-32, UNF/2B 0.179 0.174 0.380 0.570 M14 X 2 13.32 12.98 28.0 42.0
12-24, UNC/2B 0.202 0.195 0.432 0.648 f M14 X 1.5 13.49 13.24 21.0 42.0
12-28, UNF/2B 0.204 0.198 0.432 0.648 f M15 X 1 14.66 14.49 18.8 45.0
1/4A-20, UNC/1B, 2B 0.233 0.225 0.500 0.750 M16 X 2 15.32 14.98 32.0 48.0
1/4A-28, UNF/1B, 2B 0.238 0.232 0.500 0.750 f M16 x 1.5 15.49 15.24 24.0 48.0
5/16-18, UNC/1B, 2B 0.294 0.284 0.703 0.938 f M17 X 1 16.66 16.49 17.0 51.0
5/16-24, UNF/1B, 2B 0.298 0.291 0.703 0.938 f M18 X 1.5 17.49 17.24 27.0 54.0
3/8-16, UNC/1B, 2B 0.354 0.343 0.844 1.125 M20 X 2.5 19.15 18.73 40.0 60.0
3/8-24, UNF/1B, 2B 0.361 0.354 0.844 1.125 f M20 X 1 19.66 19.49 20.0 60.0
7/16-14, UNC/1B, 2B 0.413 0.401 0.984 1.313 f M20 X 1.5 19.49 19.24 30.0 60.0
7/16-20, UNF/1B, 2B 0.421 0.412 0.984 1.313 f M22 X 1.5 21.49 21.24 27.5 66.0
1/2-13, UNC/1B, 2B 0.474 0.461 1.125 1.500 M24 X 3 22.98 22.47 48.0 72.0
1/2-20, UNF/1B, 2B 0.483 0.475 1.125 1.500 f M24 X 2 23.32 22.98 36.0 72.0
9/16-12, UNC/1B, 2B 0.534 0.520 1.266 1.688 f M25 X 1.5 24.49 24.24 31.3 75.0
9/16-18, UNF/1B, 2B 0.544 0.534 1.266 1.688 f M27 X 2 26.32 25.98 40.5 81.0
5/8-11, UNC/1B, 2B 0.594 0.579 1.406 1.875 M30 X 3.5 28.81 28.22 60.0 90.0
5/8-18, UNF/1B, 2B 0.606 0.597 1.406 1.875
3/4A-10, UNC/1B, 2B 0.716 0.699 1.500 2.250 a Values in italics and parenthesis apply to zinc and magnesium only
b f = Fine Pitch Series
3/4A-16, UNF/1B, 2B 0.729 0.718 1.500 2.250 Note:
7/8- 9, UNC/1B, 2B 0.837 0.818 1.750 2.625 For both Unified and Metric Series, if hole size tolerances for D1 and D2 are
7/8-14, UNF/1B, 2B 0.851 0.839 1.750 2.625 required, in place of maximum and minimum values, the recommended
tolerance for D1 is -0.0005 in. (-0.015 mm) and for D2 is +0.0005 in. (+0.015
1- 8, UNC/1B, 2B 0.958 0.936 2.000 3.000 mm). Accurate measurement of holes with these Precision Tolerances
1-12, UNF/1B, 2B 0.972 0.958 2.000 3.000 requires measurement capability greater than what pin gages can
measure.

Values in italics and parentheses are achievable but should be discussed with the die caster prior to finalization of a casting design.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-31
 NADCA Engineering & Design: Tolerancing
S-4-11-21
STANDARD
TOLERANCES
The values shown for tapered
pipe threads represent Stan-
Cored Holes for Pipe Threads: Standard Tolerances
dard Tolerances, or normal
die casting production prac- Most pipes require taper to ensure that the connections
tice at the most economical
level. N.P.T. threads should seal as more of the thread is engaged. For example, when a X
be specified, where possible, garden hose is first threaded onto a threaded connection, it
for most efficient production. is very loose. As more of the thread is engaged by screwing D
the hose on, there is less play as the fitting gets tighter. A
good fitting will become tight before the threads bottom
out. Additional hole beyond the threads is provided so that C
fitting can be tightened against the taper to achieve the
desired seal. Taper also allows for part wear.
There are two pipe thread taper standards. National
Pipe Taper (N.P.T.) is the most common standard. A 45o
fitting should seal with at least one revolution of turn still
available on the thread. The fitting should not bottom out in the hole. Standard taper is normally
¾ inches per foot. However, taper for special applications is determined by required strength
formerly discussed in Cored Holes for Formed Threads.
Aeronautical National Pipe Taper (A.N.P.T.) is basically the same as N.P.T. pipe threads.
However, diameter, taper and thread form are carefully controlled for military and aviation use.
There is an associated cost increase using the A.N.P.T. standard since tighter controls are required.
The cored holes specified below are suitable for both N.P.T. and A.N.P.T. threads. The 1°
47’ taper per side is more important for A.N.P.T. than N.P.T. threads. There is no comparable
metric standard for pipe threads.
For the most economical die casting production, N.P.T. threads should be specified where
possible. A.N.P.T. threads may require additional steps and cost.
The required taper for all N.P.T. and A.N.P.T. sizes is 1° 47’±10’per side.
The differences in measurement of these threads represent the differences in function. The
N.P.T. thread quality in determined by use of the L1 thread plug gauge. This thread is intended
as a tapered sealing thread using pipe dope or another sealing agent to provide a leak tight seal.
The A.N.P.T. thread, as well as the N.P.T.F. (American National Taper Dryseal Pressure-
Tight Joints) thread, represents a tapered thread that is capable of sealing without the aid of
sealing agents; thus their identification as dry seal threads. These threads are checked with the
use of an L1 and L3 thread member as well as a six step plug gauge to verify thread performance
on the crests. The difference of the A.N.P.T. and N.P.T.F. is in the tolerance of the gauging. The
dry seal threads are more difficult to cast as the draft angle of the cores must be 1° 47’ per side
and without drags to avoid lobing at the tapping operation or an L3 failure.

TableS-4-11:
Table S-4A-10 Cored
Cored Holes
Holes for Tapered
for Tapered Pipe Threads
Pipe Threads Both N.P.T.
Both N.P.T. and A.N.P.T.
and A.N.P.T.
Tap size “D” Diameter Minimum Depth “X” Minimum Depth “X” “C” Diameter ±.020
for Standard Tap for Short Projection Tap
1/16 - 27 0.245 ±0.003 0.609 0.455 0.327
1/8 - 27 0.338 ±0.003 0.609 0.458 0.421
1/4 - 18 0.440 ±0.003 0.859 0.696 0.577
3/8 - 18 0.575 ±0.004 0.875 0.702 0.702
1/2 - 14 0.713 ±0.004 1.109 0.918 0.890
3/4 - 14 0.923 ±0.004 1.109 0.925 1.077
1 - 11 1/2 1.160 ±0.005 1.343 1.101 1.327
1 1/4 - 11 1/2 1.504 ±0.006 1.375 1.113 1.656
1 1/2 - 11 1/2 1.743 ±0.007 1.390 1.127 1.921
2 - 11 1/2 2.217 ±0.008 1.375 1.205 2.515
2 1/2 - 8 2.650 ±0.008 1.953 1.697 2.921
3- 8 3.277 ±0.009 2.031 1.780 3.546

4-32 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing NADCA
S-4-12-21
STANDARD
TOLERANCES

Cast Threads Threaded parts are identi-

fied by a series of numbers
known as a thread callout. A
Threads can be cast in aluminum, magnesium, or zinc. Normally, cast threads are confined to typical thread callout may be
1/16-28-0.960-0.580-0.12-
external threads where precision class fits are not required. If a precision class fit is required, the 7.02 where:
die caster should be consulted. Secondary machining may be required.
1/16 is the nominal thread size
External threads can be formed either across the parting line of a die (fig.1) or with slides (fig.
2). Tolerances shown in Table S-4-12 reflect the method by which the threads are formed. 28 is the number of Threads
The Major diameter shall be in compliance with the specified thread form definition as agreed Per Inch (TPI)
upon between the purchaser and the die caster.

Table
TableS-4-12: DieDie
S-4A-12 CastCast
Threads Tolerances
Threads Tolerances
Figure 1 Figure 2

Method of Forming PL
Threads
PL
4

Aluminum/ Aluminum/
Tolerances Zinc Magnesium Zinc Magnesium
Minimum
i pitch or maximum
number of threads per inch 32 24 32 24
0.187” 0.250” 0.187” 0.250”
Minimum O.D.
(4.763 mm) (6.350 mm) (4.763 mm) (6.350 mm)
Tolerance on thread lead per ±.005” ±.006” ±.005” ±.006”
inch of length (±.127 mm) (±.152 mm) (±.127 mm) (±.152 mm)
Minimum
i Pitch Diameter ±.004” ±.005” ±.005” ±.006”
Tolerance (±.102 mm) (±.127 mm) (±.127 mm) (±.152 mm)
Notes:
1. An additional trim or chasing operation may be necessary to remove flash formed between
threads.
2. Direct tolerances shown should be applied wherever possible rather than specifying thread
class or fit.
3. The values indicated include parting line, moving die component and linear dimension
tolerances. If tighter tolerances are required, the caster should be consulted.

Figure 3. Design Considerations

The recommended designs for terminating a die cast external thread are shown below:

OR
PL PL

chamfer
Flats on the thread at the parting line will greatly simplify the trimming operation and result in the most economical means
of producing die cast threads.
LESS DESIRABLE DESIGN MORE DESIRABLE DESIGN

PL

WHEN DIES SHIFT (DUE TO STRESS OR OTHER FACTORS),

THE THREADS WILL NOT BE ALIGNED AND CREATE MORE
PARTING LINE PROBLEMS.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-33
 NADCA Engineering & Design: Tolerancing
S/P-4-13-21
STANDARD/PRECISION
TOLERANCES
Machining stock allow-
ances are a function of linear Machining Stock Allowance (Standard and Precision)
dimensions tolerances and
parting line tolerances, and It is important to understand that the optimum mechanical properties and density of a casting
whether Standard or Preci-
sion Tolerances are required. are at or near the surface. If machining is to be performed on a casting, a minimum amount of
Precision Tolerance values material should be removed so as not to penetrate the less dense portion. However, to assure
will usually represent greater
casting accuracy involv- cleanup, an allowance must be provided for both the machining variables and the casting
ing extra precision in die variables covered by NADCA Standards in this section.
construction and/or special Datum structure is very important to help minimize or eliminate the effect of these variables.
control in production. For
economical production, they (See Datum Reference Framework in Geometric Dimensioning, Section 5, for a preferred datum
should be specified only framework.) Best results are attained if the casting is located from datum points that are in the
when and where necessary.
same die half as the feature to be machined.
Consulting with your caster early will help minimize the effect of tolerance accumulation and
Note:
No consideration was given
unnecessary machining.
to flatness in the above Normal minimum machining allowance is 0.010 in. (0.25 mm) to avoid excessive tool wear and
examples. The part shape minimize exposure of porosity. The maximum allowance is the sum of this minimum, the machin-
may dictate a flatness toler-
ance that exceeds the sum of ing allowance and the casting allowance. Machining stock is added on to existing tolerance.
the linear and across parting
line tolerances. (See Flatness
Tolerances S-4-8 and P-4-8.)
Additional machining would
then be required unless the
part can be straightened prior
Machine Stock Tolerances
0.25
to machining.
Min Machine Stock Allowance
Machining Allowance
0.2 Linear Casting Allowance
Across Parting Line Precis Tol.
Standard Hole
Tolerance in Inches

Precision Hole
0.15

0.1

0.05

0
1 2 3 4 5 6 7 8 9 10 11 12
(25.4) (50.8) (76.2) (101.6) (127.0) (152.4) (177.8) (203.2) (228.6) (254.0) (279.4) (304.8)
Length in Inches (mm)

4-34 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

Machining Stock Allowance (Standard and Precision)

Example:
Assume a 5.00 ± 0.001 in. (127 ± 0.025 mm) finish dimension on an aluminum die cast part that
is 8.00 x 8.00 in. (203.2 x 203.2 mm).
In example “A” in the table on the facing page, surface to be machined is formed in the same die half as
the datum points. In example “B”, surface to be machined is formed in the opposite half of the die as the
datum points. Both examples are shown using the Precision Tolerances for linear dimensions and parting
line. The Standard Tolerances for linear dimensions and parting line would utilize the same format.

Machining Stock Allowance Comparative Example: Precision Tolerances

Example A Example B
Datum Points Datum Points 4
In Same Die Half In Opposite Die Half
Minimum Machine Stock Allowance 0.010 0.010
(0.25 mm) (0.25 mm)
inches (mm)
Machining Allowances 0.002 0.002
(0.05 mm) (0.05 mm)
(± 0.001 in. or ± 0.026 mm)
Linear Casting Allowance 0.012 0.012
(0.356 mm) (0.356 mm)
on 5.000 in. (127 mm)
Dimension Precision Tolerance A
Across Parting Line — 0.008
(0.020 mm)
Precision Tolerances B
Maximum Stock 0.026 0.034
(0.56 mm) (0.86 mm)
Casting Dimension C 5.017 ± 0.006 5.026 +0.014/-0.006
(127.45 ± 0.18 mm) (127.66 +0.38/-0.18 mm)
A ±0.007 (±0.18 mm) P-4-1-03 Precision Tolerance
B ±0.008 (±0.20 mm) P-4-2 Precision Tolerance
C Casting dimension would not be needed if drawing was a combined drawing, only finish
dimension of 5.00 ± 0.001 in. (127 ± 0.025 mm) would be needed.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-35
 Engineering & Design: Tolerancing

Additional Considerations for Large Castings

1 Wall Thickness:
1.1: Definition: Wall thickness is the distance between two parallel or nearly parallel
surfaces. Wall thickness may vary depending on the application of draft. Wall thickness
should be maintained as uniform as possible. A general guideline would be to keep the
range of thickness within 2X of the thinnest wall. A second guideline is to keep the wall
as thin as possible to meet the castings functional requirements.
1.2: General: 0.14” (3.5mm (+/- 0.5mm)
1.2.1 Deviations: from the nominal condition are based upon product function and
manufacturing process requirements.

2 Radii:
2.1 Fillet Radii:
2.1.1 General: 0.14” (+0.08/-0.04”) [3.5mm (+2.0mm/-1.0mm)]
2.1.1.1 Deviations: from the nominal condition are based upon product function
and manufacturing process requirements.
2.1.2 Minimum: 0.060” (1.5mm)
2.2 Corner Radii:
2.2.1 General: 0.060” (+0.08/-0.04”) [1.5mm (+2mm/-1mm)]
2.2.1.1 Deviations: from the nominal condition are based upon product function
and manufacturing process requirements.
2.2.2 Minimum: 0.020” (0.5mm)

3 Cores:
3.1 Guidelines: Cores should be used to minimize machining stock, and should be pulled
perpendicular to each other. Use stepped cores where possible to minimize finish stock,
reduce heavy sections, and minimize porosity.
3.2 Minimum: Cored hole diameter to be 0.25” (6.0mm) in and parallel to the direction
of die draw.
3.3 For holes Less Than: 0.50” (12.5mm) diameter the core hole length to diameter (L/D)
ratio should not exceed 4:1.
3.4 For Holes Greater Than: 0.50” (12.5mm) diameter the core pin length to diameter (L/D)
ratio should not exceed 10:1.
*Dimensions are for larger castings. Consult a die caster to discuss capabilities for dimensioning outside of the
recommended hole length to diameter ratios.

4 Bosses:
4.1: Minimize the boss height as much as possible.
4.2: When the height to diameter ratio of the boss exceeds 1, it is recommended that ribs be
used to improve filling.
4.3: Design adjacent bosses with a minimum 0.25” (6.5mm) gap between bosses to
minimize porosity.

4-36 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
Engineering & Design: Tolerancing

Additional Considerations for Large Castings

5: Machining Stock:
5.1 General:
5.1.1: Machining stock should be minimized. Because die casting exhibit a “skin”, the
densest fine-grained casting structure is near the surface.
5.1.2: Deviations from nominal condition are based upon product function and manu-
facturing process requirements. Machine stock is added to existing tolerances.
5.2: 0.06” (1.5mm) maximum, on all faces, features found in the locator core, on remainder of part.

6 Ejector Pin Bosses:

6.1 Boss Diameter:
6.1.1: In functional areas the size and location is dependent upon product function and
manufacturing requirements.
4
6.1.2: In non-functional areas and on machined surfaces the ejector pin diameter is to
be 0.38” (10.0mm) minimum and the location is by mutual agreement of OEM and die
caster.
6.2 Surface Geometry:
6.2.1: 0.06” (1.5mm) raised to 0.03” (0.8mm) depressed.

7 Trimming & Cleaning:

7.1 Parting Lines:
7.1.1 Trim Ribs-Gate and Parting Line: 0.12” maximum (1.5mm)
7.1.2 Gates & Overflows: 0-0.059” (0-1.5mm)
7.1.3 Flash: As specified in normal standard.
7.2 Cored Holes: 0-0.02” (0-0.5mm)
7.3 Openings:
7.3.1: 0-0.06” (0-1.5mm) at the finish machined face
7.3.2: 0-0.03” (0-0.8mm) on as-cast surfaces
7.3.3: 0-0.01” (0-2.5mm) of corner radii
7.4 Corners - Sharp: Not removed.
7.5 Ejector Pin Flash (Max. Projection):
7.5.1: 0-0.12” (0-3.0mm) on machined surfaces.
7.5.2: 0-0.04” (0-1.0mm) on as-cast surfaces.
7.6 Machined Surfaces: 0.12” (0-0.3mm) max.
7.7 Seam Lines: 0-0.02” (0-0.5mm)
7.8 Negative trim (shearing): condition is allowed when the nominal wall thickness is maintained.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021 4-37
 Engineering & Design: Tolerancing

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4-38 NADCA Standards for High Integrity and Structural Die Casting Process / Section 4 / 2021
 5
Engineering & Design: Geometric Dimensioning section

Section Contents NADCA No. Format Page

Frequently Asked Questions 5-2
1 Introduction 5-2
2 What is GD&T? 5-2
3 Why Should GD&T be Used? 5-2
4 Datum Reference Frame 5-4
4.1 Primary, Secondary, Tertiary Features & Datums 5-4
4.2 Datum Feature Vs. Datum Plane 5-5
4.3 Datum Plane Vs. Datum Axis 5-5
4.4 Datum Target Sizes & Locations 5-6
5 Feature Control Frame 5-6
6 Rule #1 – Taylor Principle (Envelope Principle) 5-7
7 GD&T Symbols/Meanings 5-8
8 Material Conditions 5-8
8.1 Maximum Material Condition (MMC) 5-8 5
8.2 Least Material Condition (LMC) 5-9
8.3 Regardless of Feature Size (RFS) 5-10
9 Location Tolerances 5-11
9.1 Position Tolerance 5-11
9.2 Concentricity & Symmetry Tolerances 5-13
10 Profile Tolerance 5-14
11 Run Out Tolerances 5-18
12 Orientation Tolerances 5-19
13 Form Tolerances 5-21
13.1 Straightness 5-21
13.2 Flatness 5-23
13.3 Circulatity (Roundness) 5-23
13.4 Cylindricity 5-23
14 Conversion Charts 5-29
14.1 Conversion of Position (Cylindrical) Tolerance Zones 5-29
to/from Coordinate Tolerance Zones
14.2 Conversion of Position Tolerance Zone 5-32
to/from Coordinate Tolerance Zone
14.3 Conversion of Coordinate Measurements to 5-33
Position Location Measurements

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-1
 Engineering & Design: Geometric Dimensioning

Frequently Asked Questions (FAQ)

1) Is
 Geometric Dimensioning used on just Die Castings and why should it be used? See page
5-2 - Why should GD&T be used?
2) W hat is a Location Tolerance? See page 5-11, Location Tolerances
3) How do I convert a linear tolerance to true position? See pages 5-32 through 5-34, Conver-
sion of Position.
4) Is a list of GD&T symbols availible? See page 5-8, GD&T Symbols and Meanings.
5) W hen can I use Profile of a surface instead of flatness? See page 5-14, Profile Tolerances.

1 Introduction

The concept of Geometric Dimensioning and Tolerancing (GD&T) was introduced by Stanley
Parker from Scotland in the late 1930’s. However, it was not used to any degree until World War
II (WW II) because until then the vast majority of products were made in-house. The designer
could discuss with the manufacturing personnel (die designer, foundry foreman, machinist, and
inspectors) what features were to be contacted to establish the so called “centerlines” that were used
on the drawing to locate features such as holes and keyways. Also when two (2) or more features were
shown coaxial or symmetrical around these “centerlines”, the questions that needed to be answered
by the designer was, “how concentric or symmetrical do these features have to be to each other”?.
During WW II companies had to “farm out” parts because of the quantities/schedules. This meant
the new manufacturer had to interpret the drawing hence the “centerlines” were often established by
contacting features that were not functional or important and features produced from these incorrect
“centerlines” were not at the location required. The parts did not assemble and/or did not function
properly and had to be fixed or scrapped. GD&T was the solution to this major problem. GD&T
provides a designer the tools to have clear, concise, and consistent instructions as to what is required.
It eliminates ambiguities so that everyone involved with the part will not have to interpret the
dimensioning.
This section should be used as a handy reference guide for using GD&T with respect to the die
casting process. ASME should be consulted for a more comprehensive guide to GD&T.

2 What is GD&T?

It is compilation of symbols and rules that efficiently describe and control dimensioning &
tolerancing for all drawings (castings, machined components,etc.). It is documented in ASME
Y14.5M which has the symbols, rules, and simple examples. ASME Y14.8 is a good reference
to use for guidance on additional features for casting and forging drawings.

3 Why should GD&T be used?

GD&T is the best effort we have so far to clarify the dimensioning of a part. Die casters should
welcome and even insist upon the use of GD&T on any part prints. GD&T requirements should
be reviewed and agreed upon between the die caster and designer.
a. It is a simple and efficient method for describing the tolerancing mandated by the designer of
the part.
b. It eliminates ambiguities as to what Datum features are to be contacted to establish the Datum
planes and/or Datum axis that are to be used for locating other features. All inspection will
result in the same result – the dimension is within or out of tolerance. Fig. 5-1 illustrates a
simple example of ambiguities associated with the “old” type drawing. Fig. 5-2 illustrates the
same example with GD&T.

5-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

c. It simplifies inspection because hard gages can often be utilized and inspection fixtures are often Note: GD&T convention is to
keep units constant between
mandated which simplifies inspection for production quantities. dimensions and tolerance.
Although the examples in
d. It forces the designer to totally consider function, manufacturing process, and inspection methods. The this section are unitless
result is larger tolerances that guarantee function, but reduce manufacturing amd inspection costs. Also the numbers correspond to
the “bonus” or extra tolerance for certain conditions can result in significant production cost savings. In dimensions in inches.
addition the time to analyze whether a missed dimension is acceptable is dramatically reduced

Figure 5-1 “OLD” Drawing without GD&T.

5
Questions:

1) What is the relationship (coaxiality tolerance) between the ∅1.00 and the ∅2.00?

2) Which feature (∅1.00 or ∅2.00) is to be used for measuring (locating) the .500±.005 dimen-
sion for locating the ∅.120 hole?

Figure 5-2 “NEW” Drawing with GD&T.

Questions asked in Fig. 5-1 answered:

1) The axis of the ∅2.00 has to be coaxial with the axis of the ∅1.00 within a tolerance zone that
is a ∅.005 if the ∅ is 2.01 which is the Maximum Material Condition (MMC).

2) The ∅1.00 is the feature to be used for measuring the .500 dimension for locating the n.120
hole. The tolerance for locating the ∅.120 hole is a ∅ of .014 (the diagonal of the rectangular
tolerance zone shown in Fig. 5-1) when the hole is a MMC (∅.120).
NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-3
 Engineering & Design: Geometric Dimensioning

4 Datum Reference Frame (DRF)

The DRF is probably the most important concept of GD&T. In order to manufacture and/
or inspect a part to a drawing , the three (3) plane concept is necessary. Three (3) mutually
perpendicular (exactly 90° to each other) and perfect planes need to be created to measure from.
In GD&T this is called Datum Reference Frame whereas in mathematics it is the Cartesian
coordinate system invented by Rene Descartes in France (1596-1650). Often one would express
this concept as the need to establish the X,Y, and Z coordinates. The DRF is created by so-called
Datum Simulators which are the manufacturing, processing, and inspection equipment such
as surface plate, a collet, a three jaw chuck, a gage pin, etc. The DRF simulators provide the
origin of dimensional relationships. They contact the features (named Datum Features) which of
course are not perfect hence measurements from simulators (which are nearly perfect) provides
accurate values and they stabilize the part so that when the manufacturer inspects the part
and the customer inspects the part they both get the same answer. Also if the part is contacted
during the initial manufacturing setup in the same manner as when it is inspected, a “layout” for
assuring machining stock is not required. The final result (assuming the processing equipment is
suitable for the tolerancing specified) will be positive.

4.1 Primary, Secondary, and Tertiary Features & Datums

The primary is the first feature contacted (minimum contact at 3 points), the secondary feature is
the second feature contacted (minimum contact at 2 points), and the tertiary is the third feature
contacted (minimum contact at 1 point). Contacting the three (3) datum features simultaneously
establishes the three (3) mutually perpendicular datum planes or the datum reference frame. If the
part has a circular feature that is identified as the primary datum feature then as discussed later a
datum axis is obtained which allows two (2) mutually perpendicular planes to intersect the axis
which will be the primary and secondary datum planes. Another feature is needed (tertiary) to be
contacted in order orientate (fix the two planes that intersect the datum axis) and to establish the
datum reference frame. Datum features have to be specified in an order of precedence to properly
position a part on the Datum Reference Frame. The desired order of precedence is obtained by
entering the appropriate datum feature letter from left to right in the Feature Control Frame
(FCF) (see Section 5 for explanation for FCF). The first letter is the primary datum, the second
letter is the secondary datum, and the third letter is the tertiary datum. The letter identifies the
datum feature that is to be contacted however the letter in the FCF is the datum plane or axis
of the datum simulators. Note that there can be multiple datum sets used to reference different
features on the casting. See Fig. 5-3 for Datum Features & Planes.

Figure 5-3 Primary, secondary, tertiary features & datum planes.

5-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

4.2 Datum Feature vs Datum Plane

The datum features are the features (surfaces) on the part that will be contacted by the datum
simulators. The symbol is a capital letter (except I,O, and Q ) in a box such as A used in the
1994 ASME Y14.5 or -A- used on drawings made to the Y14.5 before 1994. The features are
selected for datums based on their relationship to toleranced features, i.e., function, however
they must be accessible, discernible, and of sufficient size to be useful. A datum plane is a datum
simulator such as a surface plate. See Fig. 5-4 for a Datum Feature vs a Datum Plane.

Figure 5-4 Datum feature vs. datum plane. 5

4.3 Datum Plane vs Datum Axis

A datum plane is the datum simulator such as a surface plate. A datum axis is also the axis of
a datum simulator such as a three (3) jaw chuck or an expandable collet (adjustable gage). It is
important to note that two (2) mutually perpendicular planes can intersect a datum axis however
there are an infinite number of planes that can intersect this axis (straight line). Only one (1) set
of mutually perpendicular planes have to be established in order to stabilize the part (everyone
has to get the same answer – does the part meet the drawing requirements?) therefore a feature
that will orientate or “clock” or “stabilize” has to be contacted. The datum planes and datum axis
establish the datum reference frame and are where measurements are made from. See Fig. 5-5 for
Datum Feature vs Datum Axis.

Figure 5-5 Datum feature vs. datum axis.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-5
 Engineering & Design: Geometric Dimensioning

4.4 Datum Target Sizes & Locations

Datum targets are datum simulators such as spherical pins or round flat bottom pins or three
(3) jaw chucks or centers that establish datum planes or a datum axis. They contact the datum
features and are often specified to be used for inspecting parts that are inherently not round or
straight or flat or they are large parts. If targets are not used then the entire datum feature has to
contact a datum simulator. An example of what can result is the part could “rock” on a surface
plate if the part was not relatively flat which would result in an unstable scenario and conflicting
results. If the datum feature is large a datum simulator that contacts the entire feature may not
exist or would be extremely expensive to produce. The datum targets are the datum planes and
datum axis and often are assembled together to create an inspection fixture and or a manufactur-
ing fixture. See Fig. 5-6 for Datum Target Sizes & Locations.

Figure 5-6 Target sizes & locations.

Component configuration shown as phantom lines on separate drawing

• Illustrates orientation when targets contact component
• Illustrates that targets are physically separate from the component
• Apply marking is shown to depict which side is to be contacted by the targets

5 Feature Control Frame

The geometric tolerance for an individual feature is specified in the Feature Control Frame which
is divided into compartments – see Fig 5-7. The first compartment contains the type of geometric
characteristic such as true position, profile, orientation, etc. The second compartment contains
the tolerance (where applicable the tolerance is preceded by a diameter symbol and followed by
a material condition symbol). The remaining compartments contain the datum planes or axis in
the proper sequence (primary datum is the first letter).

Figure 5-7 Feature control frame.

5-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

6 Rule # 1 – Taylor Principle (Envelope Principle)

When only a size tolerance is specified for an individual feature of size the form of this
feature shall not extend beyond a boundary (envelope) of perfect form at maximum material
condition (MMC). In other words, when the size is at MMC the feature has to be perfectly
straight. If the actual size is less than the MMC the variation in form allowed is equal to the
difference between the MMC and the actual size. The relationship between individual features
is not controlled by size limits. Features shown perpendicular, coaxial or symmetrical to each
other must be controlled for location or orientation otherwise the drawing is incomplete. In
other words Fig. 5-1 is an incomplete drawing. Fig. 5-8 shows the meaning of Rule #1 for an
external cylinder (pin or shaft) and an internal cylinder (hole). Note that a hard gage can be
used to inspect this principle or requirement.

Figure 5-8 Rule #1.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-7
 Engineering & Design: Geometric Dimensioning

7 GD&T Symbols/Meanings

Applied To Datum Use L or M

Tolerance Geometric Gages
Symbol Feature Feature of Reference Material
Type Characteristics Used
Surface Size Dim. Required Condition
Form Straightness +  YES YES YES***
Flatness 
YES NO
Circularity  NO NO NO
Cylindricity + ⁄⁄
Location Positional Tolerance  YES YES***
Concentricity  NO YES YES
—— NO NO
Symmetry + ———
——
Orientation Perpendicularity ⊥
Parallelism ⁄⁄ YES YES YES YES YES***
Angularity ∠
Profile Profile of a Surface ∩
YES NO YES* YES** NO
Profile of a Line ∩
Runout Circular Runout + 
YES YES YES NO NO
Total Runout + 
+ Not typically used for die cast components * Can be used to control form without a datum reference
** Datum reference only *** – Yes if M is specified for the feature of size being controlled
– No if S or L are specified for the feature of size being controlled

To improve manufacturability a designer should discuss GD&T with the die caster early in the
product design cycle.

8 Material Conditions

Features of size which includes datum features have size tolerances hence the size condition or
material (amount of metal) condition can vary from the maximum metal condition (MMC) to
the least metal condition (LMC). Consequently if the center planes or axes of a feature of size
are controlled by geometric tolerances a modifying symbol can be specified in the feature control
frame that applies the tolerance value at either the maximum or the least material condition. It
also can be specified for a datum that is a feature of size. If a symbol is not specified the tolerance
value applies regardless of material condition which is named regardless of feature size (RFS).

8.1 Maximum Material Condition (MMC)

This is the condition when the actual mating size or envelope size is at the maximum material
condition which is maximum size for an external feature such as a cylinder and the minimum size for
an internal feature such as a hole. Another way to look at MMC is that it always allows components
to be assembled. In die casting MMC is most applicable to hole positions that will be machined. The
symbol is M. The tolerance value specified for the feature being controlled in the FCF applies only
if the actual mating envelope is the MMC size. If the actual mating envelope deviates from MMC
an additional tolerance is allowed. The added tolerance is the difference between the actual mating
envelope size and the MMC size hence the largest actual mating envelope named virtual condition is
equal to the MMC size plus the tolerance specified in the FCF for an external feature and minus for
an internal feature. The MMC symbol is used to assure that parts will assemble and it allows the use
of so called hard gages (go gages) for quick inspections. An example of position with MMC is shown
in Fig. 5-9. It should be noted that actual local size has to meet the size tolerance however the actual
local size does not affect the geometric characteristic tolerance.
5-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Figure 5-9 Position control with MMC.

8.2 Least Material Condition (LMC)

This is the opposite of MMC consequently this is the condition when the actual minimum mating
size or envelope is at the minimum material condition which is minimum size for an external
feature such as a cylinder and the maximum size for an internal feature such as a hole. Another way
to look at LMC is that it always prevents components from being assembled. In die casting LMC
is most applicable to external features that will be machined. The symbol is l. Additional tolerance
is allowed if the actual minimum envelope deviates from LMC and is the difference between the
actual mating size and the LMC size hence the smallest actual mating size is equal to the LMC
size minus the tolerance specified in the FCF for an external feature and plus for an internal
feature. The LMC symbol is used to assure a minimum amount of machining stock for features
that are to be machined and for assuring a minimum amount of wall thickness between external
and internal features. Hard gages cannot be used for inspection. An example of position with LMS
is shown in Fig. 5-10. It should be noted that the actual local size has to meet the size tolerance
however the local size does not affect the geometric characteristic tolerance.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-9
 Engineering & Design: Geometric Dimensioning

ACTUAL MINIMUM
MATING ENVELOPE Ø TOLERANCE
FEATURE BEING ZONE
CONTROLLED
Ø 1.00 .005
Ø 1.01 .015

Figure 5-10 Position control with LMC.

8.3 Regardless Of Feature Size (RFS)

There is no symbol in the 1994 Y14.5 whereas it was s for the 1982 Y14.5. It is applicable if
the MMC or the LMC are not specified for individual features of size tolerances or for datum
features of size. The tolerance is limited to the specified value in the FCF and if applied to a
datum feature of size the actual axis or center plane have to be established regardless of the
feature size. It is always used for run out, concentricity, and symmetry controls as will be
discussed in those sections. It is also used when targets are specified to establish datum axes and
center planes because the targets have to contact the datum features to be useful. Also it is used
to control wall thickness variation between external and internal features. Hard gages are not
applicable since there is no additional or bonus tolerance as allowed for MMC and LMC. An
example of position with RFS is shown in Fig. 5-11.

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Engineering & Design: Geometric Dimensioning

ACTUAL MINIMUM
MATING ENVELOPE Ø TOLERANCE
FEATURE BEING ZONE
CONTROLLED
Ø 1.00 .005
Ø 1.01 .005

Figure 5-11 Position control with RFS.

9 Location Tolerances

These include position, concentricity, and symmetry tolerances. Position is used to control coaxiality
of features, the center distance between features, and the location of features as a group. Concentric-
ity and symmetry are used to control the center distance of feature elements. These three (3) toler-
ances are associated with datum’s because the obvious question is – located from what?

9.1 Position Tolerance

Positional tolerances are probably used more than any other geometric control. It is used to locate
features of size from datum planes such as a hole or keyway and used to locate features coaxial
to a datum axis. The tolerance defines a zone that the axis or center plane of a feature of size may
vary from. The concept is there is an exact or true position that the feature would be if it was made
perfect however since nothing is made perfect a tolerance zone allows deviation from perfection.
The exact location of a feature of size is defined by basic dimensions which is shown in a box
() and are established from datum planes or axes. Coaxial controls are typically a cylindrical

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-11
 Engineering & Design: Geometric Dimensioning

tolerance zone which has a diameter value and the true position is a datum axis. A positional
control is indicated by the position symbol (∅), a tolerance value (diameter symbol precedes the
tolerance value if desired), the applicable material condition modifier (m or l) if desired, and
the appropriate datum references placed in a feature control frame. When a material condition
modifier is specified a boundary named virtual condition is established. It is located at the true
position and it may not be violated by the surface or surfaces of the considered feature. Its size
is determined by adding or subtracting depending on whether the feature is an external or an
internal feature and whether the material condition specified is m or l. An example for control-
ling the location of holes is shown in Fig. 5-12 and of a keyway in Fig. 5-13.

Figure 5-12 Positional tolerancing of holes.

Figure 5-13 Positional tolerance for keyway.

Notes:
1) Datum B is the feature of size (5.000+.005) hence the true position for the keyway is the midplane of datum B.

2) No material condition modifier specified for either the keyway location tolerance .005 or the datum B, hence
the material condition is ‘regardless of feature size’ for both features.

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Engineering & Design: Geometric Dimensioning

9.2 Concentricity & Symmetry Tolerances

These both control the median points of a feature of size: concentricity ( ) is applied to circular
features (often where the part or nearby parts are rotating) whereas symmetry ( ) is applied to
non circular features. Both require that the median points of the controlled feature, regardless of
its size, to be within the tolerance zone (cylindrical zone for concentricity and two parallel planes
for symmetry). The tolerance zone is equally disposed about the datum axis for concentricity and
datum plane for symmetry. These controls are not used very often because median points are
difficult to establish due to irregularities of form and the only reason to use these controls is for
controlling the out of balance that can exist if the mass center is not close to the axis of rotation
or center plane. Examples of controlling concentricity and symmetry are shown in Fig. 5-14 &
5-15 respectively.

Figure 5-14 Concentricity tolerancing.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-13
 Engineering & Design: Geometric Dimensioning

Figure 5-15 Symmetry tolerancing.

10 Profile Tolerances
Profile tolerances can control the location, orientation, and form of a feature that has no size (sur-
face). There are two (2) types – profile of a surface (∩) and profile of a line (∩). The exact or true
profile of a feature is established by basic dimensions of radii, angular dimensions, and coordinate
dimensions established from datums however a profile tolerance can be specified to an individual
surface without specifying a datum – see Fig. 16. The elements of a profile (outline of an object in a
given plane) are straight lines or arcs. The tolerance is a boundary of two (2) parallel planes disposed
(equally – see Fig. 17 or in one direction – see Fig. 16) and normal (perpendicular) along the perfect
or true profile within which the entire surface must lie. The profile can be controlled between two (2)
points – see Fig 16. Also if datum planes are established by targets – see Fig. 18 the tolerance zone
is equally disposed about the datum planes whereas if the datum planes are established by complete
contact with the datum features the tolerance zone is unidirectional and ½ the tolerance value in the
FCF – see Fig. 17 vs Fig. 18.

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Engineering & Design: Geometric Dimensioning

Figure 5-16 Profile control – unidirectional and between points.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-15
 Engineering & Design: Geometric Dimensioning

Notes:
1) All surfaces to be within .02±.01 tolerance zone of true or perfect profile.

2) Datum A B and C to be within .01 of datum planes A, B, and C.

Figure 5-17 Profile control – all around entire part without targets.

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Engineering & Design: Geometric Dimensioning

Figure 5-18 Profile control – all around entire part with targets.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-17
 Engineering & Design: Geometric Dimensioning

11 Run Out Tolerances

Run out tolerances control the relationship of a feature relative to a datum axis established from one
(1) diameter or two (2) diameters separated axially – see Fig. 5-19. The material condition applied to
the feature being controlled and the datum feature or features is always RFS because 360° rotation is
required to conduct the inspection. If targets are not specified to establish the datum axis the entire
datum feature has to be contacted which may not be practical. There are two (2) types of run out
controls – circular () and total (). Circular run out controls the cumulative variation of circular-
ity (roundness) and coaxiallity for features constructed around a datum axis and circular elements of
a surface constructed an angle not parallel to the datum axis (control wobble). The tolerance is the
full indicator movement (FIM) for each circular element independently as the part is rotated 360°.
For each measurement the dial indicator is removed from the part after each 360° rotation and reset
at a new location. Total run out controls the entire surface simultaneously hence it controls cumula-
tive variations in circularity, coaxiality, straightness, taper, angularity, and profile of a surface. The dial
indicator is not removed from the part after each 360° rotation. If applied to surfaces that are at an
angle to the datum axis it controls variation in angularity (wobble) and flatness (concavity or convex-
ity). See Fig. 5-19 for circular run out and Fig. 5-20 for total run out.

Figure 5-19 Circular runout with targets.

5-18 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Figure 5-20 total runout with targets.

12 Orientation Tolerances

There are three (3) separate orientation tolerances however two (2) of the three are specific values
of the general tolerance named angularity. The two (2) specific tolerances are named perpendicu-
larity (90° to a datum) and parallelism (180° to a datum). These tolerances control the orientation
of features to a datum plane or axis. Angularity controls a surface (non feature of size), a center
plane or an axis of a feature of size to a specified angle and its symbol is ∠. Perpendicularity
symbol is ⊥ and parallelism symbol is ⁄⁄ and they do the same as angularity except the angles
are specific as previously stated. The tolerance zone may be either two (2) parallel planes at the
specified basic angle from a datum plane or axis within which the surface, center plane or axis
must lie or it may be a cylindrical zone within which the axis of the considered feature must lie.
Of course if angularity tolerance is specified for a feature of size the material condition modifiers
m or l may be specified. If neither m or l is specified then as always the regardless of feature
size (RFS) is applicable. See Fig’s 5-21 thru 5-23 for examples of ∠, ⊥, and ⁄⁄.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-19
 Engineering & Design: Geometric Dimensioning

Figure 5-21 Angularity of a feature of size axis at MMC.

Figure 5-22 Perpendicularity of a feature of size axis at MMC with datum feature of size at MMC.

5-20 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Figure 5-23 Parallelism – surface.

13 Form Tolerances

There are four (4) form tolerances : straightness, flatness, circularity, and cylindricity. They apply
to individual features therefore the tolerances are not related to datums. Straightness can be used
to control the straightness of median line of a feature of size hence material condition modifiers
can be applied. The other form tolerances control surfaces hence material condition modifiers are
not applicable.

13.1 Straightness
There is one symbol () for straightness but there are two (2) kinds of controls that are very
different from each other. One control is for line elements of surfaces (FCF attached to the
surface) and the other is control of an axis or median plane of feature of sizes (FCF attached to
the size tolerance). The axis or median plane control relaxes the form control provided by Rule #1
because a perfect form boundary at MMC can be violated if the M symbol is specified. Fig. 5-24
illustrates control of line straightness and Fig’s 5-25 & 5-26 illustrate control of axis and median
plane straightness respectively. The surface straightness tolerance is only for line elements in the
view that the FCF is attached.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-21
 Engineering & Design: Geometric Dimensioning

Figure 5-24 Straightness of a surface.

Figure 5-25 Straightness of an axis RFS.

5-22 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Figure 5-26 Straightness of an axis at MMC.

13.2 Flatness
Flatness controls the distance between the high and low points of a surface. The tolerance zone
is the distance between two parallel planes that have no particular orientation. All elements of
the entire surface must lie between these two planes. See Fig. 5-27 for an illustration of flatness
control. The symbol is . Flatness is the same as straightness of a surface except straightness
controls line elements only in the view that the control is applied whereas flatness controls the
entire surface, i.e., all views.

13.3 Circularity (Roundness)

Circularity controls each circular element of a cylinder independent of each other. The circular ele-
ments of the surface in a plane perpendicular to an axis must lie between two concentric circles whose
radii differ by the tolerance value in the FCF. The symbol is . See Fig. 5-28 for an illustration.

13.4 Cylindricity
Cylindricity controls the entire surface of a cylinder. The tolerance zone is two (2) concentric
cylinders parallel to the axis of the actual mating envelope. The radii of the concentric cylinders
differ by the tolerance value specified in the FCF. It is a composite tolerance that controls
circularity, straightness, and taper. The symbol is ⁄⁄. See Fig. 5-29 for an illustration.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-23
 Engineering & Design: Geometric Dimensioning

Figure 5-27 Straightness of an axis at MMC.

Notes:
Each circular element in a plane perpendicular to an axis must be between two concentric circles with radii
that differ by .002. Also each element must be within the size limits.

Figure 5-28 Circularity.

5-24 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Notes:
Cylindrical surface has to lie between two concentric cylinders with radii that differ by .01. Also the surface
must be within the specified size tolerance.

Figure 5-29 Cylindricity.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-25
 Engineering & Design: Geometric Dimensioning

-A-
A2 A3
2.00 C1

1.50

-B-
0.50
6.00 2.00

-C-
Center Line
P/L
A1
A. Top View Eject

B. End View

-C-
B1 B2 0.75
Eject
-A-
X X

P/L Core Slide

5.00 2.00

C. Side View

D. Isometric View

(All Target Areas on Same Side of P/L)

Figure 5-30 Example of an optimal datum reference framework for a die cast part design (all datums on same side of p/l).

5-26 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

P/L

-A-
A2 A3
2.00 C1

1.50

-B-
0.50
6.00 2.00

-C-
Center Line

A1
A. Top View B. End View

-C-
6.00 2.00

Eject
-A-

3.00
P/L Core Slide
5
X X

B1 B2

C. Side View

D. Isometric View

(Target Areas A and C on Opposite Side of P/L From Target B)

Figure 5-31 Example of a less desirable datum reference framework for a die cast part design (datums across p/l).
May require additional qualification of some datums.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-27
 Engineering & Design: Geometric Dimensioning

-A-
A2 A3 1.30
2.00

1.50

-B-

6.00 2.00

-C-
C1 Center Line
P/L
A1
A. Top View Eject

B. End View

-C-
6.00 2.00

Eject
-A-

1.70
P/L Core Slide

X X

B1 B2

C. Side View

X
D. Isometric View

(Datum A is on Opposite Side of P/L from Datum B) C1

(Datum C is located on moving die component)

Figure 5-32 Example of a least preferred datum reference framework for a die cast part design (datums across p/l
and datum on moving component). Will require qualification of all datums.

5-28 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

14 Conversion Charts

Coordinate dimensioning defines parts by their location on a three-dimensional grid, utilizing

the X-Y-Z coordinate system as in Fig. 5-2. Since the Coordinate Dimensioning System may
not consider part function when defining dimensions and tolerances, GD&T is a preferred
method of defining and dimensioning parts based on functional relationships to other parts and
part features. Sometimes it is necessary for dimensions and tolerances to be converted from one
system to the other. Geometric dimensioning and tolerancing is steadily replacing coordinate
dimensioning as more emphasis is placed on “designing for manufacturing” early in the product
design stage. This section will demonstrate how to convert between coordinate dimensioning and
geometric dimensioning.

14.1 Conversion of Position (Cylindrical) Tolerance Zones

to/from Coordinate Tolerance Zones
When converting total position (cylindrical) tolerance zones to total coordinate tolerance zones,
a general rule of thumb is that total coordinate zone is approximately 70% of total position
tolerance zone. This is only useful for non-critical applications. For example, for a non-critical
part to be converted from position (cylindrical) tolerance zone to coordinate tolerance zone, the
position (cylindrical) tolerance is multiplied by 0.7 (70%). The total coordinate tolerance zone is
then divided by 2 to obtain the bilateral tolerance zone.
Figure 5-33 visually demonstrates the conversion from coordinate tolerance zone to position
(cylindrical) tolerance zone.
5

.007 .007
Total TPositional
otal P osTitional
olerance Zone
T olerance
Diameter
Zone(C) D iameter (C )

.0 025
45°

.005 (B)

.0025
9 0° 45°

Total Coordinate
T otal or Bilateral
Coordinate or B ilateral
. 0025 . 0025 Tolerance Z one
T olerance Zone

.0 05 (A)

Figure 5-33 Conversion of positional (cylindrical) tolerance zones to/from coordinate tolerance zones.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-29
 Engineering & Design: Geometric Dimensioning

Figure 5-34 Conversions chart for converting between position tolerance and coordinate tolerance.

5-30 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
Engineering & Design: Geometric Dimensioning

Total Coordinate Tolerance Zone =

[Total Position (Cylindrical) Tolerance Zone] X [0.7]

Example: Bilateral Tolerance Zone = [Total Coordinate Tolerance Zone] / 2

Sometimes parts require a more precise conversion. When a critical application is required, the
conversion factor is 0.70711. The position tolerance will be multiplied by 0.70711 (70.711%) to
obtain the total coordinate tolerance.

Total Coordinate Tol. Zone = [Total Position (Cylindrical) Tol. Zone] X [0.70711]

Bilateral Tolerance Zone = [Total Coordinate Tolerance Zone] / 2

For example, to convert 0.007 total position (cylindrical) tolerance to total coordinate
tolerance:

Total Pos. Tol. Zone X Conversion Factor = Total Coordinate Tolerance Zone
0.007 Tol. X 0.70711 = 0.00495 ~ 0.005 Tot. Coordinate Tol.

Or
5
Total Coordinate Tol. Zone / 2 = Bilateral Tol. Zone 0.005 / 2 = 0.0025 Bilateral Toler-
ance

The following example demonstrates a simple conversion from total position tolerance zone to
total coordinate tolerance zone and bilateral tolerance zone. Figure 5-36 visually demonstrates
the conversion from position (cylindrical) tolerance zone to the coordinate tolerance zone.
When converting from total coordinate tolerance zone to total position (cylindrical) tolerance
zone, the total coordinate tolerance zone is multiplied by 1.4142. A bilateral tolerance zone is
multiplied by 2 then multiplied by 1.4142 to obtain the total position (cylindrical) tolerance zone.
For non-critical applications, it is acceptable to multiply the total coordinate tolerance zone
by 1.4 to obtain the total position tolerance zone. A bilateral tolerance may be multiplied by 2 to
obtain the total coordinate tolerance zone, then multiplied by 1.4 to get the total position tolerance
zone.

Total Position Tol. Zone =[Total Coordinate Tol. Zone] X [1.4142]

Total Position Tol. Zone = [Bilateral Tol. Zone] X [2] X [1.4142]

For example, to convert .005 total coordinate tolerance to total position (cylindrical)
tolerance:

[Total Coordinate Tolerance Zone] X [Conversion Factor] = Total Position Tol. Zone
[0.005 Total Coordinate Tol. Zone] X [1.4142] = 0.007 Total Tol. Zone
Or
[Bilateral Tolerance Zone] X [2] X [Conversion Factor] = Total Position Tol. Zone
[0.0025 Bilateral Tol.] X [2] X [1.4142] = 0.007 Total Tol. Zone

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-31
 Engineering & Design: Geometric Dimensioning

14.2 Conversion of Position Tolerance Zone to/from Coordinate Tolerance Zone

Figure 5-34 is a chart for converting position tolerance zones to coordinate tolerance zones, and
for converting coordinate tolerance zones to position tolerance zones.
When looking at the conversion chart in Fig. 5-34, coordinate tolerance zones are listed across
the top of the grid and increasing from left to right, and on the right side of the grid increasing
from bottom to top. The position tolerances are listed on the left side of the grid and increase
from bottom to top. The position tolerances, however, follow the arced line across the grid. The
diameter of a position tolerance is given on the drawings, however, the diameter of a coordinate
tolerance is given by the length of the diagonal line. A diagonal line is drawn from the lower left
corner of the grid at a 45° angle to the upper right corner of the chart. The diameter is calculated
by using A 2 + B2 = C2. In figure 5-33, A is the total length of the horizontal line at the bottom
and connected to the circle, squared, plus B, the square of the vertical line at the left or right
edge and connected to the circle. Take the square root of the sum of the two sides will equal the
diameter C.
For example, suppose one wanted to convert a 0.010 diameter position tolerance to a coordi-
nate tolerance. While looking at the chart in Fig. 5-34, begin at the 0.01 position tolerance on
the left side of the chart. Follow the corresponding arced line until it crosses the diagonal line
on the chart. Where the arced line and the diagonal line intersect, follow the horizontal line
across to the right side of the chart. The number on the right side of the chart that corresponds
with the horizontal line will give the appropriate bilateral coordinate tolerance. In this example,
the corresponding bilateral tolerance is ± 0.0035. To quickly verify this conversion, use the
multipliers identified in on page 5-31. Multiplying the coordinate tolerance by 0.7 will yield the
total coordinate tolerance. This number is then divided by 2 to obtain the bilateral coordinate
tolerance.

Position Tolerance = 0.010

Total Coordinate tolerance = Position Tol. X Conversion Factor = [0.010] X [0.7] =
0.007
Bilateral Tolerance Zone = Total Coordinate Tolerance / 2 = [0.007] / [ 2] = ±0.0035

Bilateral Position Tol. = ± 0.0035

Total Position Tol = Bilateral Position Tol. X 2 = [0.0035] X [2] = 0.007
Position Tol. X Conv. Factor = [0.007] X [1.4] ~ 0.01

The number obtained from the conversion chart and the number obtained by using the multiplier
should be approximately the same.
Suppose it was desired to convert a coordinate tolerance such as 0.007 to a position toler-
ance. In order to use the conversion chart in Fig. 5-34, the coordinate tolerance must be in
bilateral coordinates, so 0.007 is divided by 2. This yields a bilateral coordinate tolerance of
± 0.0035. Next, the number .0035 is located on the left side of the conversion chart. Follow
the corresponding horizontal line across to the left until it intersects the diagonal line. At this
intersection, follow the intersecting arced line all the way across and to the left. The number
corresponding to that arced line on the left of the chart gives the associated position tolerance.
If done correctly, the position tolerance identified on the chart should be 0.010. This can be
double-checked by using the multipliers on page 5-31.
The number obtained from the conversion chart and the number obtained by using the
multiplier should be approximately the same.
To convert between position tolerancing and coordinate tolerance, either the conversion table
identified in Fig. 5-34, or the multiplication factor identified on page 5-31 may be used.

5-32 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
 Engineering & Design: Geometric Dimensioning
Conversion of Coordinate
Measurements to
Position Location
f Coordinate
ts to
tion

Figure 5-35 Conversions chart for converting between coordinate measurement and position measurement.

Figure 5-36 Schematic of conversion of coordinate measurements to position location.

14.3 Conversion of Coordinate Measurements to

Position Location Measurements
In addition to sometimes having to convert between position tolerance zones and coordinate
tolerance zones, it is also necessary to convert coordinate measurements to position location
measurements. When converting from coordinate measurements to position measurements, the
chart identified in Fig. 5-35 is used.
For example, if it was necessary to convert the position measurement 0.0311 to coordinate
measurements the following steps need to be accomplished. First, locate the number 0.0311
on the chart in Fig. 5-35. Once the number is located, follow the vertical column down to the
X-axis of the chart. The number identified at the very bottom of the column is the X-coordinate
measurement. In this example, the X-coordinate is 0.011. Now, relocate the number 0.0311
on the chart and follow the horizontal row to the right until it crosses the Y-axis. The number
on the very left end of that row is the Y-coordinate measurement. In this example, the
Y-coordinate is 0.011. Since position measurements are three-dimensional, a Z-coordinate must

NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021 5-33
 Engineering & Design: Geometric Dimensioning

also be identified. To find the corresponding Z-coordinate measurement, a simple equation

must be performed. This equation is as follows:

Z = 2√ X2 + Y2

For this example, Z = 2 times the square root of X squared plus Y squared.

Z = 2√ (0.011)2 + (0.011)2
Z = 2√ (0.000121) + (0.000121)
Z = 2√ 0.000242
Z = 2√ 2(0.015556)
Z= 0.031112

The coordinate measurements that are associated with the 0.0311 position are

X = 0.011, Y = 0.011, and Z + 0.031112.

5-34 NADCA Standards for High Integrity and Structural Die Casting Process / Section 5 / 2021
 6
Engineering & Design: section
Additional Specification Guidelines
Section Contents NADCA No. Format Page
Frequently Asked Questions (FAQ) 6-2
Introduction 6-2
1 Pressure Tightness G-6-1-21 Guideline 6-3
2 Fillets G-6-2-21 Guideline 6-4
3 Ribs and Corners G-6-3-21 Guideline 6-5
4 Ejector Pins, Pin Marks and Pin Flash G-6-4-21 Guideline 6-6
5 Metal Extension (Flash) Removal G-6-5-21 Guideline 6-7
6 Surface Finish, As-Cast G-6-6-21 Guideline 6-8
7 Die Cast Lettering and Ornamentation G-6-7-21 Guideline 6-10

NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021 6-1
 Engineering & Design:
Additional Specification Guidelines
Frequently Asked Questions (FAQ)

1) H
 ow much flash can be expected to remain on a die casting after degating and trimming?
See page 6-7, Metal Extension (Flash) Removal.
2) If lettering is cast into the part, what are the options? See page 6-10, Die Cast Lettering.
3) A re ejector pin marks required on the casting and will they have flash? See page 6-6,
Ejector Pins, Pin Marks and Pin Flash.
4) W hat is a typical pressure tightness that die castings can withstand? See page 6-3,
Pressure Testing.
5) W hat is the best surface condition I can expect on die cast surfaces? See page 6-8,
Typical As-Cast Surface Roughness Guide.
6) W hy add ribs to the casting in-place of thick sections? See page 6-5, Ribs and Corners.

Introduction
The die casting specifications discussed in this section relate to aspects of die casting design
and production for which precise standards are difficult to set forth. As in previous Engineering
sections, they replace the former ADCI/NADCA “E” Series.
They include characteristics which are highly dependent on the design and shape of the
particular part to be die cast, such as:
• Pressure tightness of the finished part
• The proper design of fillets, ribs and corners in a part
• The consideration of ejector pin locations, pin marks and pin flash
• Casting flash and its removal
• As-cast surface finish specifications
• The casting of lettering, logos and ornamentation on the part surface
The purpose of this section is to offer established engineering and design guidelines which,
if implemented, can produce the most economical results under normal die casting operations.
These conditions should be made in close consultation with a die casting partner prior to any
final design decisions.

1 Pressure Tightness in Cast Parts

Assurance of pressure tight castings is highly dependent on the design configuration of the part.
Consultation with the caster in the early design stages is essential where a specification for pressure
tightness exists, in order to take advantage of basic product design, casting die design, and produc-
tion processing factors. All of these factors are involved in insuring pressure tightness of the final
cast part.
While most cast part designs can be cast pressure tight, specific castings may require impregna-
tion to achieve required pressure tightness.

Special Notification Required

Specifications for pressure tightness will require deviations from standard production and inspec-
tion practice. Special pressure testing equipment and testing procedures are usually needed.
The requirement for pressure tightness should be made only where it is essential to the perfor-
mance of the finished part. Where so specified, test methods and inspection procedures should
be agreed upon in advance between the customer and the caster. Duplicate test fixtures and test
methods are recommended wherever possible.
The discussion of “Porosity” and “Pressure Tightness” under Quality Assurance, Section 7 of
this manual, should be reviewed.

6-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021
Engineering & Design: NADCA
Additional Specification Guidelines G-6-1-21
GUIDELINES

Guidelines for Pressure Tightness Pressure-tightness speci-

fications for die castings,
Important considerations relating to the economical production of pressure-tight castings include to assure containment of
liquids or gases in use,
the following guidelines: require deviations from
standard production and
inspection practice. Extra
1.1 Product Design and Die Design steps, including special
pressure-testing equipment
Successful casting of pressure-tight castings requires close conformance to the following principles and testing procedures, are
of good casting product design to ensure quality within the die casting component: usually needed.

a. Guidelines concerning fillets, ribs and corners (G-6-2 and G-6-3), in this section, should be followed
very carefully.
b. Part wall sections should be of uniform thickness as much as possible.
c. Holes and passages requiring pressure tightness should be cored to reduce porosity, as opposed to
machined after casting.
d. Ample draft should be provided in all cored holes and passages which are not to be machined. Cored
holes which are to be machined should be given minimum draft (see Draft Tolerances pg. 4A-21).
e. Heavy sections, as well as abrupt changes in sectional thickness, should be avoided.
f. Special vacuum casting techniques may be required in addition to special steps in temperature control,
the use of squeeze pins and other procedures to achieve final part specifications where the part design
does not conform to good casting design guidelines.

1.2 Secondary Machining

The outer section, or skin, of a die casting consists of a dense, fine grain microstructure which
gives the casting greater strength and durability. For pressure tight applications, strict limitations
to secondary machining operations must be observed to ensure adequate performance. The 6
following guidelines are provided:
a. A minimum amount of machining stock should be removed, to avoid exposing porosity by cutting
deeply into a casting (see Machining Stock Allowance Tolerances, located in the Engineering &
Design:Tolerancing section of this manual).
b. Large draft angles, which would require the removal of a large amount of stock from a surface to be
machined, should be avoided, particularly where holes are cored.
c. Machining both sides of the same section of a pressure-tight casting should be avoided.
d. Where machining can expose porosity, impregnation may be required to insure pressure tightness.

1.3 Die Casting Alloy Selection

Certain alloys are best for producing pressure-tight castings. Refer to the Alloy Data sections
for alloy comparisons of pressure-tightness characteristics to aid in the selection of the most
favorable alloys.

1.4 Casting Requirements & Pressure Testing

Pressure-tightness testing for castings is generally specified in the range of 5 to 40 psi. Higher
pressures will require special consideration by the caster and will be almost entirely a function of
the part design.
In the case of pressure-tight casting requirements, review inspection procedures in Commer-
cial Practices (Section 8), and Porosity Control (Section 2). It is important that the die caster and
customer agree to the pressure decay system (ie. bubble test, pressure decay, etc.) and the medium
specification (ie. hydrogen, nitrogen, etc.) for the pressure test to prevent confusion later in the
production cycle.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021 6-3
 NADCA Engineering & Design:
G-6-2-21 Additional Specification Guidelines
GUIDELINES

These recommendations
regarding the design of 2 Fillets in Die Cast Parts
fillets, ribs and corners rep-
resent guidelines which will
result in die casting at the
most economic level under Fillets
normal production practice.
Sharp inside surface junc- Intersecting surfaces forming junctions are best joined with fillets to achieve improved quality in
tions, acute angle corner both the die casting component and die casting die. Fillets function to:
conditions and delicate, • Distribute stresses in areas of the die casting which improve the strength and performance
deep and closely spaced ribs
should be specified only of the die casting
where and when necessary, • Dissipate heat buildup during the casting process which helps avoid potential shrinkage
since additional costs may
be involved. porosity due to “hot spots” that can occur at sharp corners in die castings
• Improve die life by distributing stress and eliminating hot spots in the die
In the sketches below, consideration has been given to the normal stresses on the die cast part in
use and to the stresses induced in the die castings by the casting process itself, as well as to other
manufacturing and die maintenance considerations.

Fillet Draft
Fillets projected in a direction normal (perpendicular) to the parting line require draft. The amount
of draft is always governed by the draft of the intersecting surface (see Section 4), if a constant fillet
radius is maintained.

Shallow vs. Deep Die Casting Designs

These suggestions apply to fillets on corners which are projected normal to the parting plane in die
castings of moderate depth. Shallow die castings may have much smaller fillets, while deep pockets
and other inside corners should have larger fillets.

Avoid Long, Sharp Corners

Long, sharply squared corners projecting in a direction normal to the parting plane may cause
spalled edges on the die casting and should be avoided.

Recommended Fillet Designs and Allowances Less Desirable

WHERE T1 = THICKNESS OF THINNEST METAL AT JUNCTION
R1 Too Large R1 Approaching
WHERE T1 = T2 ANGULAR TRANSITION Zero
T1 TEE JUNCTION T1
R1 R1
T1
R1
T2 R1 R1

POINT OF
TANGENCY Fig. 8 Fig. 9
HEAVY MASS HERE DIFFICULT TO
R2 NOT CONDUCIVE MAINTAIN
Fig. 1 Fig. 2 TO SOUND METAL. IN DIE.
0
IF R 2 = R1 + T1; R1 = T1 TEE JUNCTION T2
WITHOUT R1 = T1 TO 11/4 T1 T1 + T2 2(T1 + T2) Not Recommended
LIMIT 2 Fig. 3
cross
IF R 2 = 0; + R1 = T1 TO 11/4 T1 ANGULAR TRANSITION
INCREASES STRENGTH
CORSS OR “Y” JUNCTION BUT COSTLY DIE WORK. NO FILLET
WHERE T2 > T1 Θ
T1

R1 DEFLECTOR
R2
T1
Θ Fig. 10 Fig. 11
R1 WEAK CASTING, DIFFICULT TO MAINTAIN IN DIE.
R2
T2
Fig. 6
R1
T1
Fig. 7
Fig. 4 Fig. 5 R1
R2 DEPRESSION PROMOTES
Θ = 90˚; ALL RADII EQUAL T1 DENSITY, ESPECIALLY
2/
R1 = (T1 + T2)
3 Θ = 45˚; R1 = 0.7 T1 R1 = 1.5 T1 UNDER CYLINDRICAL
SHARP Fig. 12
R 2 = 0 TO R1 + R 2 BOSSES, BUT ADDS
Θ = 30˚; R1 = 0.5 T1 R1 = 2.5 T1 IRREGULAR EDGE-DIFFICULT TRIMMING
TO DIE COST.

NO FILLETS

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12

6-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021
Engineering & Design: NADCA
Additional Specification Guidelines G-6-3-21
GUIDELINES

These recommendations
3 Ribs and Corners in Die Cast Parts regarding the design of
fillets, ribs and corners rep-
resent guidelines which will
result in die casting at the
Ribs most economic level under
normal production practice.
Correctly designed ribs are used to efficiently increase the stiffness of, or add strength to, a die casting Sharp inside surface junc-
tions, acute angle corner
and to aid in making sound die cast parts, without the use of excess material. Often, ribs add more conditions and delicate,
strength to die castings than solid material. If designed incorrectly, ribs can be a detriment if working deep and closely spaced ribs
should be specified only
stresses are concentrated by their use, or if high stresses are created at the edges of the ribs by their where and when necessary,
incorrect design. Considerations to rib design are given in the following topics and sketches. since additional costs may
be involved.
External Corners
Sharply squared external corners may be used in some locations if die construction permits. This
type of corner is mandatory at parting line locations and die block intersections. Elsewhere,
corners of die castings should have radii to prevent early die failure, to reduce the probability of
nicking the edge of the die casting in handling and assembly, and to minimize material handling
hazards for personnel.
Small Metal Savers
Ribs are often an integral part of making a die casting stronger, but a die cast part designer
needs to be cognizant of the steel as well. The empty space left in between ribs that serves no
functional purpose on the part is called a metal saver. Often, adding ribs close together can
result in thin or weak metal savers required in the die cast die to form the rib features in the
part. The designer should review the part for:
• Relatively deep metal saver pockets
• Relatively sharp edges to metal saver pockets
• Relatively small draft on the sides of the metal saver pockets
6
All of the above should be avoided when designing the die cast part. The die caster or tool maker
can be consulted for design suggestions as well.

Recommended Rib Designs and Allowances Not Recommended

R
h
SHARP CORNERS —
BLEND
T1 SMALL RADII.
h T1 T1
Fig.8
Fig. 1 Fig. 2 Fig. 3
NO RIBBING — BOSS
h = T1 WHERE h > T1 CORE OUT UNDERNEATH BLENDING AS SHOWN EXTENSIONS LESS
TO AVOID UNDESIRABLE HEAVY MASS OF METAL. MAY BE DESIRABLE. DESIRABLE FOR
CASTABILITY
BLEND Fig.9

RIBS INSIDE — GOOD DISTRIBUTION

OF METAL FOR ALL PURPOSES. RIB

Fig. 4 EXTERNAL RIBS MAY CAUSE

POOR DISTRIBUTION
OF STRESS
Fig.10

Fig. 7 SHARP CORNERS —

Fig. 5 Fig. 6 SMALL RADII —
RIB FROM FLANGE TO BOSS —
LITTLE DRAFT
GOOD DISTRIBUTION OF STRESSES GENEROUS DRAFT AND FILLETS —
NOTE ANGULAR TRANSITION. Fig.11

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11

NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021 6-5
 NADCA Engineering & Design:
G-6-4-21 Additional Specification Guidelines
GUIDELINES

The guidelines presented

here for the location of 4 Ejector Pins, Pin Marks and Pin Flash
ejector pins, pin mark
tolerances and procedures
regarding pin flash repre-
sent standard die casting Ejector Pin Marks Ejector
Ejector Pin
Pin Operation
Operation
production practice at the
most economic level. Dis- Moveable ejector pins must be used to eject a die casting
regarding these guidelines from the die casting die and will result in a residual ejector
should be done only when
and where essential to the pin mark on the die cast part.
product design, since addi- In addition to automatically pushing the casting from the
tional cost may be involved.
die after part solidification, ejector pins also serve to keep
the casting from bending.
The sequential illustrations at right demonstrate the action
of the ejector pins in a die casting cycle.

Location Of Ejector Pins

Ejector pin locations should be at the option of the die caster,
subject to the customer’s agreement. Where considerations FigureAA
Figure
of cast surface cosmetics are important, ejector pin locations Retracted Ejector Pins
should always be discussed in advance of die design.
The number, size and location of ejector pins and bosses
required will vary with the size and complexity of the die
casting, as well as with other factors.

Acceptable Ejector Pin Marks

Ejector pin marks on most die castings may be raised or
depressed .015” (.381 mm). Raised ejector pin marks are
preferred for optimum production. Larger castings may
require additional ejector pin tolerances for proper casting
ejection.
Figure B
Ejector Pin Operation Figure B
Extended
With each die casting cycle, the die opens and the ejector
plate in the ejector half of the die (Fig. A) automatically
moves all ejector pins forward (Fig. B), releasing the casting from the die. Then, the die casting
is removed from the die manually or mechanically.
Ejector pin diameters should be as large as possible to reduce the chance of bending or breaking.

Ejector Pin Flash

Ejector pin marks are surrounded by a flash of metal. Normally, ejector pin flash will not be
removed, unless it is objectionable to the end use of the part.
Alternatively, ejector pin flash may be specified as crushed or flattened.
In the case of either nonremoval or crushing/flattening, flash may flake off in use.
Complete removal of ejector pin marks and flash by machining or hand scraping operations
should be specified only when requirements justify the added expense.
Figure C
Bumping Ejector Pins
When ejector pins are placed on a flat surface, it can sometimes cause the side opposite the
ejector pin to bulge out on the part (called bumping). Bumping can be minimized by:
• Increasing the wall thickness (increasing locally is an option as well).
• Placing ejector pins near walls (distributes some ejection force to ribs).
• Placing ejector pins on top of ribs.
• Increasing draft.
• Placing bosses where ejector pins are located

6-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021
Engineering & Design: NADCA
Additional Specification Guidelines G-6-5-21
GUIDELINES

The guidelines for removal

5 Metal Extension (Flash) Removal of die casting metal exten-
sion (flash) presented here
represent normal produc-
tion practice at the most
economic level. Precision
Metal Extension (Flash) Formation and Location flash trimming, closer
than standard commercial
An extension of metal is formed on die castings at the parting line of the two die halves and trimming, or the complete
where moving die components (also called moving die parts) operate (see Figure 6-1). removal of all exten-
A seam of metal extension may also be formed where separate die parts cast a part feature. sion involves additional
operations and should
Residual metal extension is also formed by the normal operation of ejector pins and is discussed be specified only when
on the previous page. requirements justify the
additional cost.

Simplifying Extension (Flash) Removal

Necessary casting metal extension removal costs can be reduced by consideration, in the design
stages, of the amount of metal extension to be removed and the removal method to be employed.
Early consultation with the die caster can often result in production economies in the treat-
ment of metal extension removal.

Guidelines to Extent of Removal

The table below provides a guide to the types of die casting metal extension (flash) which occurs
in typical die castings and the amount of metal extension material which remains after (1)
degating (removal of any gates and runners from the casting), and (2) commercial trimming of
die casting metal extension.
Note that in some instances, where special surface finish characteristics are not involved, the
most economic method of degating and metal extension (flash) removal may include a tumbling
or vibratory deburring operation.

Guide to Nominal Metal Remaining by Type of Extension

6
Type of Metal Extension and Nominal Amount Remaining After Degating and Trimming
Thick Gates & Thin Gates & Parting Line and
Operation Metal Extension Sharp
Overflows Overflows Seam Line Metal
Description in Cored Holes Corners
> 0.12” (3.0 mm) < 0.12” (3.0 mm) Extension
After Degating Rough within Rough within Excess Only Not Not
Nominal Flash Remaining 0.12” (3.0 mm) 0.12” (3.0 mm) Broken Off Removed Removed
After Commercial
Within Within Within Removed within Not
Trimming*
0.06” (1.59 mm) 0.03” (0.8 mm) 0.015” (0.38 mm) 0.010” (0.25 mm)** Removed
Nominal Extension Remaining
* “Commercially trimmed” does not include additional operations to remove loose material. For very heavy gates and overflows, consult
your die caster.
** Shave trimming may be available to reduce amount of metal remaining in cored holes. Consult your die caster to determine what
options are available.

Figure 6-1: Examples of complex parting lines that can make flash extension removal more difficult.
(transparent shaded areas represent flash extensions)

NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021 6-7
 NADCA Engineering & Design:
G-6-6-21 Additional Specification Guidelines
GUIDELINES

The as-cast external surface

finish classifications shown 6 Surface Finish, As-Cast
here illustrate variations in
production practice. Surface
finish requirements should
be specified for production
at the most economic level. General Guidelines for As Cast Surface Finish on Die Cast Parts
Generally, extra steps in
die design, die construction The specification of external surface finish requirements is desirable for selected die casting
and casting production are applications and, in the case of some decorative parts, essential.
required for the more exact- The purpose of the guidelines presented here is to classify as-cast surface finish for die castings
ing finishes, and additional
cost may be involved. into a series of grades so that the type of as-cast finish required may be addressed and defined in
Selection of the lowest advance of die design.
classification number, com-
mensurate with the die cast These guidelines should be used for general type classification only, with final surface finish
part application, will yield quality requirements specifically agreed upon between the die caster and the customer.
the lowest cost. The first four classes listed relate to cosmetic surfaces. Class five relates to selected surface
areas where specified surface finish limitations are required.

As-Cast Surface Finish Classifications and Final Finish or End Use

Class As-Cast Finish Final Finish or End Use

No cosmetic requirements. Surface Used as-cast or with protective coatings;
Utility
1 Grade
imperfections (cold shut, rubs, surface
porosity, lubricant build-up, etc.) are
Anodize (non-decorative)
Chromate (yellow, clear)
acceptable
Surface imperfections (cold shut, rubs, Decorative Coatings:
surface porosity, etc.), that can be Lacquers
Functional
2 Grade
removed by spot polishing or can be
covered by heavy paint, are acceptable.
Enamels
Plating (Al)
Chemical Finish
Polished Finish
Slight surface imperfections that can Structural Parts
Commercial be removed by agreed upon means are (high stress areas)
3 Grade
acceptable. Plating (Zn)
Electrostatic Painting
Transparent Paints and Coatings
No objectionable surface imperfec- Special Decorative Parts
Consumer tions. Where surface waviness (flatness), Plating
NOTE: 4 Grade
noted by light reflection, is a reason for
rejection special agreement should be
Electrostatic Painting
Transparent Paints and Coatings
As-cast surface finish clas-
sification does not apply
reached with the die caster.
to machined surfaces. Surface finish, applicable to limited O-Ring Seats or Gasket Areas
Finished machined surface Superior
requirements shall be as
agreed upon between the
5 Grade
areas of the casting and dependent on
alloy selected, to have a maximum value
die caster and customer and in micro inches as specified on print.
separately identified on the
engineering part drawing.

Typical As-Cast Surface Roughness Guide

Typical Surface Roughness (m-inches)
Alloy Family / Alloy Expected in a New Die Over the Life of a Die
Aluminum, ZA-12, ZA-27 63 or lower 100-125
Magnesium 63 or lower 63 should be maintainable
Zinc, ZA-8 32 or lower 63 should be maintainable
Notes:
1. Part design, gate location, draft, flow lines, die surface treatments and other factors can impact surface roughness.
2. Roughness values for Over the Life of a Die do not include heat checking in the die.
3. Die lubricants utilized for special applications may impact surface roughness and the values in the table may not be achievable.

6-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021
Engineering & Design:
Additional Specification Guidelines
Legend for Advantages:
Coatings for Castings 1 Corrosion
Coating Applicable Material Advantages Price** protection
A lodine 5200 A l, Mg 1, 2, 3 Low 2 Chemical
PRETREATMENTS

resistance
Chromate (Class 1A & 3) A l, Zn 1, 2, 3, 4 Low 3 Adhesion
enhancement
I ron Phosphate A l, Mg, Zn 1, 3 Low
4 Conductivity
N H 35 Mg 1, 2, 3 Low
5 Flexibility
Urethane A l, Mg, Zn 1, 3, 5 Medium 6 Hardness/
Epoxy A l, Mg, Zn 1, 2, 3, 6 Medium wear resistance/
durability/
PRIMERS

Z inc Rich A l, Mg, Zn 1, 2, 3, 6 High mar resistance

Z inc Chromate A l, Mg, Zn 1, 2, 3, 5, 6 Medium 7 UV resistance
Vinyl Acid Wash Al 1, 2, 3, 5 Low 8 Decorative finish
E -Coat A l, Mg, Zn 1, 2, 3, 6 Low
Urethane A l, Mg, Zn 1, 3, 5, 6, 7 Medium
Epoxy A l, Mg, Zn 1, 2, 3, 6 Medium
TOPCOATS
LIQUID

*A nodizing of aluminum

A crylic A l, Mg, Zn 1, 3, 5, 6, 7 Medium is contingent upon the
specific alloy and may
Waterbase A l, Mg, Zn 1, 2, 3, 5, 6, 7 Medium not yield an aesthetically
F luropons/ Architect A l, Mg, Zn 1, 2, 3, 5, 6, 7 High pleasing surface.

Polyester A l, Mg, Zn 3, 5 Low

OPERATIONS

** Comparison of coat-
T GIC A l, Mg, Zn 1, 2, 3, 5, 7 Medium ing prices should be
6
POWDER

made with a constant

COATS

Urethane A l, Mg, Zn 3 , 5, 7 Low cast material. Prices for

coating aluminum will
Epoxy A l, Mg, Zn 1, 2, 3 Medium be higher than prices for
coating zinc.
Hybrid A l, Mg, Zn 1, 2, 3 Medium

A nodize A l*, Mg 1, 2, 3, 5, 6, 7 Low

ANODIC
FILMS

H ardcoat - Hard Anodizing A l, Mg 1, 2, 3, 6, 7 Medium

C opper A l, Mg, Zn 1, 2, 4, 6, 8 High

C opper/Nickel A l, Mg, Zn 1, 2, 4, 6, 8 High
ELECTROPLATING

Cu/Ni/Chrome A l, Mg, Zn 1, 2, 4, 6, 8 High

Brass A l, Zn 1, 2, 4, 6, 8 High
Bronze A l, Zn 1, 2, 4, 6, 8 High
Z inc A l, Zn 1, 2, 4, 6, 8 High
S ilver A l, Zn 1, 2, 4, 6, 8 Very High
G old A l, Zn 1, 2, 4, 6, 8 Very High
ELECTROLESS

E lectroless Nickel A l, Mg, Zn 1, 2, 3, 4, 6, 8 High

PLATING

E lectroless Copper A l, Mg, Zn 1, 2, 3, 4, 6, 8 High

For more details contact a viable coating source.

Note: Not all die castings readily accept electro-coatings. Vacuum plating films such as PVD and CVD coatings,
mechanical plating such as Zinc/Tin, and thermal spray coatings may also be applied. Consult with the the
applicable coating suppliers.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021 6-9
 NADCA Engineering & Design:
G-6-7-21
GUIDELINES
Additional Specification Guidelines
The guidelines presented
here for incorporating logo-
types, lettering and orna- 7 Die Cast Lettering and Ornamentation
mentation in a die cast part
represent normal production
practices at the most eco-
Lettering, medallions, logotypes, trademarks and a range of identification symbols may be
nomic level. Fine detail in reproduced on the surfaces of die cast parts.
lettering and art styles can Such as-cast ornamentation may be raised or depressed, but note that raised lettering will
be achieved but may involve
additional costs. result in lower die construction costs and reduced die maintenance over the life of the die.
Raised lettering on a depressed panel can be an economical substitute for depressed letters, as
shown in the illustration below.

Cast-in Lettering/Ornamentation Guidelines

In addition to the avoidance of depressed lettering or symbols in the casting surface, the follow-
ing guidelines will achieve the most satisfactory results. The terms used refer to the illustrations
below.
1. The Line Thickness (or “ face”) of any letter to be clearly cast should be 0.010 in. (0.254 mm) or greater.
2. The Height (or raised dimension) of a cast letter or symbol should be equal to or less than the line thickness.
3. The Draft Angle should be greater than 10°.
4. Letters or symbols containing fine serifs or delicate lines cannot be expected to die cast cleanly.

Sample Letter Three Alternative Die Cast Effects

or Symbol LINE (OR FACE)

SIZE

DRAFT DRAFT DRAFT

ANGLE ANGLE ANGLE

HEIGHT HEIGHT

RAISED DEPRESSED RAISED IN

(PREFERRED) (NOT RECCOMENDED) DEPRESSED PANEL

Fig. 1a Fig. 2a Fig. 3a

Fig. 1b Fig. 2b Fig. 3b

6-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 6 / 2021
 7
Quality Assurance section

Section Contents Page

Frequently Asked Questions (FAQ) 7-2
Introduction 7-2
1 Balancing Process Capabilities with Product Requirements 7-2
1.1 The Engineering/Quality Team 7-2
1.2 Standard vs. Precision Tolerances 7-3
1.3 Lean Manufacturing 7-3
1.4 Simulation 7-3
2 Defining Product Quality 7-7
2.1 Internal Defects 7-7
2.2 External Defects 7-8
3 Drawings and Specifications 7-8
4 Gage, Measurement and Testing Equipment 7-9
5 First Article Inspection Requirements (FAIR) 7-9
6 Statistical Quality Control 7-10
6.1 SPC Procedures 7-10
6.2 Process Variables 7-10
6.3 Capability 7-11
6.4 PPM Levels 7-12
7 Porosity 7-12
7.1 Internal Porosity 7-13
7.2 Parting-Line Porosity 7-14 7
8 Pressure-Tight Castings 7-14
9 Structural Quality Assurance 7-16

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-1
 Quality Assurance

Frequently Asked Questions (FAQ)

1) I s there information available about porosity in a die casting?

See pages 7-12 through 7-16 starting at Porosity.
2) W hat process variables affect the quality of die castings?
See page 7-10, Process Variables.
3) W here can information on die casting defects be found?
See page 7-7, Internal Defects.
4) W hen should CP or CPK be used?
See page 7-12, Capability.
5) I s a simulation really necessary?
See page 7-3, Simulation.
6) W hat are some typical images of porosity and/or breakout at parting lines?
See pages 7-13 through 7-15, Porosity.
7) C an x-ray be used to view porosity?
See page 7-13 and 7-15.

Introduction

Continuing advances in die cast processing and control technologies allow the specifier of die
castings today to achieve very high levels of precision.
However, custom production requirements that are beyond readily manageable process
capabilities can increase costs. It is therefore essential that the user of die castings discuss process
capabilities with the die caster early to keep costs in line with expectations.
This section deals with the control of the variables in die casting production to achieve the specifications
presented in the earlier Engineering and Design Sections. It is the aim of this section to clarify terminology
and establish the criteria necessary to maintain acceptable product quality under normal die casting practice.
Communications by means of purchase orders, part drawings, CAD/CAM databases, corporate
standards, manufacturing specifications, die casting industry standards and guidelines should all
be used to clarify the job content. Working together to clearly define areas in doubt will obviously
result in optimum service at lowest costs.

1 Balancing Process Capabilities With Product Requirements

The best opportunity to reduce costs and enhance quality lies in carefully specifying those
characteristics that are clearly needed in the product, i.e., distinguishing between critical and
less critical features. When the functional requirements have been clearly defined, the die caster
can determine, in advance, the precise processing steps necessary to achieve them.

1.1 The Engineering/Quality Team

Developing the optimum set of product requirements consistent with process capabilities is best
accomplished by forming a cross-functional engineering and quality team involving all parties
who are concerned with the success of the product.
Often called a “concurrent engineering” or “simultaneous engineering” team, it should include
representatives of design engineering, manufacturing engineering (from both the die caster and
customer), quality assurance and marketing.1
If a formal cross-functional engineering team is not set up, an informal team of key personnel
from both the customer and the die caster should be formed to meet several times during the
product development process to address important questions.

7-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

1.2 Standard vs. Precision Tolerances

The die casting process can offer very high casting precision, as discussed under “Standard” and
“Precision” Tolerances in “Engineering and Design,” Section 4A. Precision Tolerance levels
should be specified only when product requirements justify the additional production steps that
may be required. Otherwise industry Standard Tolerances should be used.
It is always advantageous, in terms of faster delivery and lower production costs, to avoid
unnecessarily stringent tolerances and specifications.

1.3 Lean Manufacturing

The term “Lean” is used to describe a manufacturing process. Lean is continually striving for
perfection, continually declining costs, zero defects, zero inventories, and an increase in business.
There are five major principles used in “Lean Thinking!”
• Value: Only the ultimate customer can determine value!
• Value Stream: All the actions and services required to bring a specific casting to market.
• Flow: Flow is a continuum from the order desk to the shipping dock. No stopping or storing!
•  P ull: The customer can pull the product from the caster because of the quick turnaround
time. Pulling is like turning on a switch for the desired product.
• Perfection: There is no end to the process of reducing effort, time, space, cost, and mistakes.
Lean employs five principles, but we will use two of those principles to highlight our improve-
ment for Product Integrity. Value Stream is one of those concepts: “All the actions and services
required to bring a specific casting or family of castings to market in a logical, timely sequence
that promotes perfection. Perfection is an overriding principle for our premise of improvement:
“Make sure we know exactly what the customer wants.”

1.4 Simulation
Software tools such as CAD/CAM, shot monitors, and simulation programs all assist the
industry in optimizing the process. These tools are used in the industry in order to increase
quality and efficiency. When NADCA metal flow principles are properly employed, it increases
the probability for sample castings to be approved. The use of simulation software can ensure
proper placement of runners, gates, overflows, and venting/vacuum. Finally, when a shot monitor
is employed, the engineering and process departments can easily determine whether the machine
7
is achieving the simulated conditions. Casting process simulation can also assist in cooling line
design, process design, and stress and distortion analysis. It may take several simulation itera-
tions to ensure an ideal design is created.
There are many automated features on the die cast machine, trim dies, and subsequent
machining operations. If the mold is not producing an acceptable casting the speed created is not
in the Perfection Mode of Lean Thinking.
For example, the following steps are used for a typical metal flow simulation:
• Engineering will create a 3-D model of the casting with runners and gates connected and export
the file in an STL format for the simulation. A PQ2 analysis will yield the desired fill time and
optimum gate area. The gate depth and location can be determined for the simulation.
• A fast simulation, in the initial design stage can be made to ensure the position of inlets will
yield the desired perfection. This is a critical stage to ensure the holder and mold will be
oriented for machining. The neglect of this sequence in the value stream may result in weld-
ing and refashioning runners & gates, resulting in a time and material loss. If the gates have
to be moved the outcome may result in a shortage of tool steel for the new gates. Emphasis
must be placed on the proper sequence to avoid mistakes, rework and ultimate delays in the
delivery of the mold. Perfection is a must at this step in the value stream.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-3
 Quality Assurance

Critical questions to ask at this critical stage are:

• Does the inlet gate satisfy the feeding of each cavity?
• Is the last place to fill well defined? (Figure 7-1)
• Are the overflows and/or vacuum lines in the last place to fill?
• Are there areas that may be porous or not filling properly? (Figure 7-2)
• Does it seem the gates are placed correctly? (Figure 7-3)
• What are the casting quality requirements?
• What and where are the functional areas?
• Has a PQ2 analysis determined gate size and filling speed? (Figure 7-4)
• Has the casting been checked for square corners or areas of difficult fill? (Figures 7-5)
• Will major changes have to be made to ensure perfection?
• If the simulation determines a change, the recommendations are put into a new model and
STL for another iteration. If it seems the gate is adequate or a slight change is needed the
mold can be aggressively machined.

Figure 7-1: Temperature result showing splashing with the poten- Figure 7-2: Velocity result showing challenges of filling bosses
tial for cold shut and lamination

Figure 7-3: Air pressure in a casting correlating to outgassing on Figure 7-4: Filling pattern showing cold, solidifying metal potentially
a cosmetic, plated casting causing a flow defect

7-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-5: Filling pattern showing air pockets in the casting after Figure 7-6: Fraction liquid of a casting showing the disconnection
all overflow and vents are blocked of the gate and intensification

7
Figure 7-7: Total displacement showing casting shrinkage and Figure 7-8: Example of the residual stresses on the casting after
distortion with a 25 times scale factor ejection and cooling to room temperature

Simulations can be used to optimize heat flow, determine the location of cooling lines and cooling
requirements. Simulations can also be used to predict die distortion, casting ejection temperatures and
dimensional capability, last place to fill, and areas of poor fill or non-fill, and pockets of porosity. They
also indicate where the overflows should be placed as indicated by the last area of the casting to fill.
A time and cost saving for the entire supply chain is to have accurate information for the mold-maker
to complete the mold building. Time and price increase when the project is delayed because of minute
changes or uncertainty of design. The customer, caster, and mold maker must all be informed of the
part design and specific areas of special concern. All questions must be answered so every party can be
aggressive in executing their expertise. Then the project can mature in an orderly and speedy fashion.

FAQ Concerning Simulation:

What is the value or benefit of a simulation?
The simulation will give an accurate, graphic depiction of the filling process and will verify the suggested
gating profile. Many times a runner and gate are cut only to find the results are not in the perfection
mode of desirability. The simulation must be done prior to cutting steel.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-5
 Quality Assurance

Are the simulation results easy to understand or read?

It requires a skilled engineer or experienced person to explain the results. Any computer literate indi-
vidual can create the simulation, but experience is required to understand the results.
Is the simulation cost effective?
If a caster or mold maker owns the software it can and should be used on every project. There are also
consultants who will be cost effective in conducting a simulation. The process saves countless hours of die
changes, welding and machining of gates to enhance flow. The relative small cost of the simulation saves
time, money and increases the availability for increased business. The true reward for a proper value
stream sequence is realized when the project goes into production as a result of careful planning and timely
execution. All the members of the value stream make a profit and have capacity for increased business.

Finite Element and Finite Difference Methods

Both finite element and finite difference methods are used to numerically solve the partial dif-
ferential equations that describe physical phenomena including heat transfer, fluid flow, stress,
displacement, distortion and others. Both techniques require discretizing the object or spatial
domain of analysis into a grid of nodes and applying numerical techniques to solve the problem of
interest at these nodes. The main differences in the methods arise from differences in the solution
techniques used.
Finite difference uses a grid of points, almost always uniform, and the derivatives present in
the differential equations are approximated by differences constructed using neighboring points,
hence the name. The problem is thereby reduced to a set of simultaneous equations that are
solved iteratively. Because the grid is uniform, finite difference grids may not perfectly follow the
surface of the object and may have a stair step like appearance. Newer grid generation procedures
minimize these effects but not all finite difference-based programs support them.
Finite element also discretizes the space into a grid, but it is not necessarily uniform. Instead the
spatial domain of the analysis is decomposed into discrete elements. The elements generally are
polyhedra either with 6 rectangular sides and 8 corner nodes (brick elements) or four triangular
sides and 4 corner nodes (tetrahedral elements). Accurate tetrahedral meshes are easily created
by automatic meshing programs. Because of the meshing procedure FE meshes provide excellent
surface fidelity.
Finite element methods solve the differential equations by using an approximate solution defined
within the element in terms of the solution value at the nodes. Neighboring elements share nodes
and the solution much match at these nodes leading to a set of simultaneous equations that must be
solved consistent with specified boundary condition. Each element has so called fitting functions
that are used to interpolate the solution within the elements and, because the element contains the
approximate solution, different element types are required for each type of problem to be solved.
That is, even with the same geometry and mesh, different elements are used for heat transfer and
stress analysis for example. Finite elements will always have nodes at the corners and may have
nodes at the center of each edge and at the center of the element depending on the element type
and the solution approximation technique that is used. Even with the extra nodes, finite element
meshes generally contain a smaller number of nodes than a finite difference grid for the same
problem.
In principle either technique can be used to solve the differential equations of any of the
common engineering problems although finite difference tends to be the method of choice for fluid
dynamics problems (such as metal flow analysis) and finite element for stress and deflection. Both
methods handle heat flow equally well. For either type of system, there can be wide differences
in the implementation of a particular type of solution across vendors. Also, for both special and
general purpose packages, not all will have the ability to address nonlinearities such as contact
and movement between components of the system (e.g., contact between the die and the machine
platen or contact between the casting and cavity wall). The quality of the solution depends more on
the quality of the implementation than on the method.

7-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-9: 2D illustration of the difference between finite difference and finite element meshes.

2 Defining Product Quality

The definition of product quality is fitness for end use. The definition will vary from
design to design and usually varies for different areas of the same part.
The designer should expect to commit sufficient time and resources with the custom die
caster, in the preliminary design stages before final drawings are completed, to determine
what constitutes casting defects, and to precisely define acceptable product quality. This
critical step will reduce rejections and rework, promote smooth operations between the
die caster and the customer’s design and procurement staff and increase successful results.
The checklists C-8-1 and C-8-2, which appear at the end of Commercial Practices,
Section 8, should be used in specifying quality requirements.
It is rarely, if ever, practical to eliminate all casting discontinuities. Any attempt at total
elimination will usually increase the cost of the casting unnecessarily.
There are two general types of discontinuities: internal and external. Internal defects
can affect the structure of the casting, and may or may not be visible on the surface. 7

Figure 7-10: Magnified view of a non-metallic inclusion as an

example of an internal defect other than porosity.

2.1 Internal Defects

Porosity is the most common type of internal defect (see page 7-13 Internal Porosity). In many
cases internal porosity will have little or no effect on the overall strength and integrity of a casting.
Where pressure tightness for a gas or liquid application is not a requirement, a mechanical
strength test (by a standard weight drop or torque wrench application) per an agreed upon
sampling plan can be a cost-effective approach to quality assurance for casting strength.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-7
 Quality Assurance

2.2 External Defects

External, or surface defects, do not generally affect the structure of the casting. Surface defects are
especially sensitive to the particular design of gates and runners in the die casting die. Calculated
design parameters using proven metal flow design and process simulation techniques have been
shown to be very effective.
The type and severity of external defect that can be accepted depends greatly on the type
of final surface treatment to be applied. For example, a powder coating application deposits a
relatively thick coat compared with painting systems, and will tolerate greater levels of surface
roughness. Bright plating, such as chrome or brass, requires a very smooth surface finish.
Surface finish standards for die castings are normally developed on a part-by-part basis between
the producer and the user.
It is important that the final finish acceptance standards developed be understood and agreed
upon by all parties, with reference to a specific viewing standard such as “no objectionable
imperfections, as specified, when viewed under normal lighting conditions at XX feet viewing
distance.” This can be addressed on checklist C-8-2, in Section 8, checklist item Q.
Reference sample standards should be retained by all parties after agreement on the accept-
able standard.
Some common types of surface defects that may occur in production over time are cold shuts
(knit lines), swirls (surface roughness), build-up (die lube or soldering accumulation) and heat
checking (very small raised fins on parts). See Guideline G-6-6 Surface Finish, As-Cast on
page 6-8 for more details.

Figure 7-11: Examples of external defects.

Heat checking occurs during the life of a die when small cracks appear in the die due to thermal
cycling. They sometimes cause concern on structural features because they appear, to the untrained
eye, as cracks on a part. However, they do not affect the structural integrity of the casting, and are
not generally objectionable on structural features that do not have cosmetic requirements.
Raised fins are routinely removed by surface blasting with shot or grit, or by vibratory finishing
(which is normally the procedure used to prepare the surface for painting). How external defects
are to be removed or eliminated depends on the type of surface finish required, whether painted,
plated, or functional. The method to be used should always be discussed with the die caster. For
more information on die casting defects see NADCA publication #E-515 Die Casting Defects –
Causes and Solutions.

3 Drawings and Specifications

To insure uninterrupted production to specifications at the most economical level, it is important to

supply all drawings and specifications to the die caster with the “Request for Quotation” (RFQ ).
For correlation purposes, it is necessary that the drawings and specifications contain the
following information:
1. Dimensions or areas that are of critical, major or minor importance, and the Acceptance Quality Level
(AQL) or Parts-Per-Million (PPM) level to which they will be checked, including the dimensions for
which the customer will be requesting control charts.

7-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

2. Datum locations to be used for machining or gaging and the areas to be used for special checking
3. The gaging procedures the customer intends to follow and the special gages that will be furnished.
4. Special requirements and the areas to which they pertain.
5. Coded surfaces on parts to be plated, painted, etc., designating classification of surfaces.
6. Indication as to where die trimmed edges are not acceptable and specification of degree of metal exten-
sion removal required (See “Metal Extension,” G-6-5, in Section 6).
7. Indication of any engineering change level requirements by purchase orders and accompanying drawings.
8. Specification of those surfaces which may not be used for location of the ejector pins.
9. A list of generic print tolerances which will adequately describe all the non-critical areas on the print.
10. Clear description of all standards for approval or rejection.
Providing detailed and complete specifications at the time of the RFQ will benefit both the customer
and the supplier. It will enable the die caster to submit more accurate, competitive quotes and help assure
that the customer will receive quality die castings at the most economical level.

4 Gage, Measurement and Testing Equipment

Proper gaging equipment must be provided for effective measurement of product conformance.
The customer is expected to furnish special-purpose gages which are required for inspection of
specific die castings.
Special gaging requirements should be stated and the responsibility for maintenance of special gages
should be established on the RFQ and on subsequent contracts between the die caster and customer.
Gaging labor, when applicable, is included in the price quoted for the die casting.
When special gaging fixtures are necessary, they should be made in duplicate by the customer
and one set furnished to the die caster. The customer should also furnish complete inspection
methods and gage design information to the die caster at the time of the request for quotation. A
gage and measurement instrument calibration system, with records maintained by the die caster,
will assure consistent measurement control.
It is also suggested that gage Reproducibility and Repeatability (R & R) studies be done on all

7
customer-supplied special gages. Further, it is recommended that all gaging sets be qualified by
both the customer and die caster.
The responsibility for any preventative maintenance to be performed on customer-owned gaging
should be made clear.

5 First Article Inspection Requirements (FAIR)

Whether the die caster or the customer is to perform the inspection of initial samples produced
from a die casting die should be decided at the time the purchase order is issued.
When the inspection of initial samples is completed by the die caster, a report of the findings
will be submitted to the customer. This is frequently referred to as a First Article Inspection Report
(FAIR). Unless otherwise specified, first piece samples are supplied for dimensional check only.
(Inspection of initial samples by the die caster may result in added cost.)
At the customer’s request, the die caster will be responsible, after the inspection of initial samples, for
correction of tooling for out-of-specification part dimensions before the start of production.
The customer should change the print for those dimensions for which tooling correction is not
required in order to agree with the initial samples report. The general print tolerance will apply to
the changed dimensions as noted, unless there is agreement to a new tolerance. Any automotive or
other industry requirements such as preproduction approval pieces (PPAP) should also be known at
the time of quoting. See figure 7-20 on an example PPAP flow chart.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-9
 Quality Assurance

In the event a print change will not be made, the customer should furnish an inspection report
specifying those dimensions or tooling corrections which are not required. Any dimension not
requested to be corrected or changed on the print is considered a valid dimension with normal
tolerances, after the start of production, for the life of the tool.
The customer must acknowledge part acceptance by a formal letter before production is run.
Such acknowledgment indicates either conformance to print or acceptance of a permanent
deviation from specifications. The general print tolerances will apply to any deviations. Any die
castings received by the customer which conform to the approved sample dimensions will be
considered acceptable product.
If capability studies are to be done at the time of first-piece inspection, or in place of first piece inspec-
tion, this requirement should be specified at the time of the RFQ. Any automotive or other industry
requirement such as Pre-Production Approval Process (PPAP) should be known at the time of quoting.

6 Statistical Quality Control

To assure uniform quality control standards acceptable sampling procedures and tables for
inspection by attributes, such as ANSI/ASQC Z1.4, should be used.
Characteristics to be inspected for product conformity should be agreed upon by the customer
and supplier prior to the first production run.
The classification of particular characteristics and AQL or PPM levels should be determined at
the time the contract is negotiated. Classification of defects (critical, major, minor) should be in
accordance with the latest revision of the acceptable sampling procedures to be utilized.
Normal inspection, as per ANSI/ASQC Z1.4 for instance, should be used.
Sampling plans to be used by the die caster will be left to the discretion of the individual die
caster, recognizing, however, the responsibility to meet the agreed upon AQL or PPM levels.

6.1 SPC Procedures

Where the current revision of ANSI/ASQC Z1.4 is not desired or appropriate, a negotiated
standard of sampling and acceptance should be established prior to die design, with early determi-
nation of SPC recording. Any requirement for process potential data or process capability studies
should also be outlined at that time.
Dimensions and/or parameters requiring SPC data and Cp and Cpk values should be agreed
upon by the customer and die caster prior to the first production run. This should include types of
SPC charts, subgroup size, and sampling frequencies.
Determination must be made prior to production as to all specific SPC reporting requirements,
data maintenance and its transmission. The die caster should be expected to point out to the
customer the impact on Cpk values when cast die features are built on the “steel safe” or “wear safe”
side of nominal, to allow the tooling maximum tool life and wear towards nominal dimensions.

6.2 Process Variables

There are five process variables that affect the quality of the die casting:
1. Metal analysis
2. Metal temperature
3. Die temperature
4. Die lubricant characteristics
5. Die filling conditions
In general, die casting is a setup-dominant process that exhibits variation of a serial, rather
than random, nature. Of the five variables only No. 5, “die filling conditions,” exhibits the “con-
tinuous drift” variation that the traditional X bar-R control charts were conceived to monitor.
Variables 2 and 3, metal and die temperature fluctuations, exhibit more of “cyclic drift” and
are thus not well suited for periodic inspection associated with traditional SPC. A continuous
monitoring system is better suited to measure the variability of temperature-related process

7-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

variables. Monitoring within part variation will document significant temperature differences
that can occur.
Variable 5, die filling conditions, consists of the elements of the shot profile that shot monitor-
ing equipment can monitor and measure. Capability studies can be used to establish the range
in the shot profile that the process will produce in casting production. More often than not,
changes in the shot profile due to random, constant-cause conditions are minimal compared with
the non-random conditions that are traceable to machine maintenance requirements.
Any special production requirements should be reviewed early with the die caster. Not all die
casters may be able to apply SPC to machine parameters and may have to monitor the process, or
the results of the process, through a less sophisticated method.

6.3 Capability
Capability studies have become increasingly more popular in the last several years. In the past, SPC and
capability studies were tools used mainly by machine houses, but more and more die casters are being
required to do them to qualify the die cast tooling. Capability studies can be very important in determin-
ing process ranges as well as helping to determine PPM levels. However, misuse of Cp vs. Cpk can take
away much needed process variation and tool life in the die casting operation.
Due to the pressures used in the die cast process, several variables can come into play. These
include parting line separation, mismatch at the parting line, core slide blow back and core slide
shift or a combination of the above. Normally, dimensions that are affected by these conditions
are built into the die cast die on the low side of the tolerance range. These dimensions should be
considered as a plus side tolerance dimensions only.
In addition, the die cast process can be very abrasive on the die surface causing rapid tooling

Figure 7-12: Cp is the raw capability index or in simpler Figure 7-13: Cpk is the Total Process Capability or =
terms = repeatability. accuracy and repeatability.

Normal Distribution
0.5
99.95
0.4
99.73
0.3
98.76
0.2
0.1
0
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6

Figure 7-15: CPK indicates a normal distribution that

Figure 7-14: Cp can be applied to a bimodal distribution allows within the distribution the maximum allowance of
that allows for migration from one side of the tolerance plus/minus tolerance that yields the greatest number of good
range to the other. The higher the Cp number the more parts in production. The higher the CPK number the more
repeatable the process is. repeatable and accurate the process is.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-11
 Quality Assurance

wear. Part features that are affected by this wear are normally built on the high side of the toler-
ance range. These dimensions should be considered as a minus side tolerance dimension only.

(USL-LSL)
Cp = (6 x s)

(X-LSL) (USL-X)
Cpk = (3 x s) Cpk = (3 x s)

On as-cast features Cp should be used as the primary measurement if the dimension targeted is in
tolerance and on the right side of the tolerance range. For example a cast hole dimensioned at 2.000
+/- 0.010 (50.8mm +/- 0.25mm) checks 2.008 with a Cp index of 6.0 and a Cpk of +0.85, should be
considered a good dimension to yield maximum tool life and process repeatability.
On cored hole locations and machined features Cpk should be used as the primary measure-
ment. For example a machined hole dimensioned at 2.000 +/- 0.010 (50.8mm +/- 0.25mm)
checks 2.008 with a Cp index of 6.0 and a Cpk of +0.85, should be considered as bad and the
size adjusted to get closer to 2.000.

6.4 PPM Levels

PPM goals and requirements are becoming increasingly popular in the procurement of die castings
and die cast assemblies. Since the part complexity, customer requirements and level of processing
contribute to the reject level, a threshold PPM level is not specified by NADCA.
Process capability studies may be used to assist in predicting PPM levels for specific castings,
secondary processes, and/or assemblies. Ultimately, the PPM goal or requirement should be as
agreed upon between the die caster and customer.

7 Porosity

It is usually necessary to address porosity when specifying die castings. While porosity specifications
are very difficult to define generically, there are existing guidelines that provide a good starting point.
Solidification begins at the surface of die castings and progresses to the center generating two
distinct zones in each wall section, as shown in Figure 7-16. The skin, which has finer grain
structure, begins at each surface and extends inward to a typical thickness of .015 to .020 in. (.38
to .50 mm). This area is usually free of porosity compared to the center of the section. The porosity
is located between the skins in the core. The finer grain structure and absence of porosity give the
skin superior mechanical properties. Skin thickness of a die casting is relatively constant and is not
a function of total wall thickness; therefore, thin-wall sections can actually be stronger and more
consistent than thick sections. The removal of the skin to a depth greater than .020 in. (.50mm) by
secondary processes, such as machining, increases the chance of exposing porosity in the core as
can be seen in Figure 7-17. These important points are not widely recognized by designers.
Exterior or surface porosity can be identified with the naked eye, magnification or with
penetrant inspection methods.
The as-cast surface is more dense than the core, and hence, stock removal by machining should be
minimized. The die caster should be aware of critical areas as porosity can be managed to large extent
via gating, overflows, chills and various process parameters.
Castings can be inspected utilizing non-destructive inspection techniques NDT. When speci-
fied, reasonable detection levels should be employed. Non-destructive testing methods for internal
porosity detection include ultrasound (UT), radiography/X-ray (film, real-time, ADR automatic
defect recognition), eddy current (EC) and various weight techniques. Methods for external
porosity detection include visible and fluorescent die penetrant (DPI).
If porosity is a major concern due to leakage/pressure tightness issues, the employment of a
pressure test should be considered.

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Quality Assurance

Porosity in Dense, Dense, Porosity in

center section chilled skin chilled skin center section

Figure 7-16: Skin Effect

Due to rapid solidification
in the die, a die castings
outer skin has a dense,
f ine grained structure
with a higher strength
than underlying metal.
According to Borland and
Tsumagari (2007), the skin
extends inward to a typical
depth of 0.38 to 0.50mm
(0.015 to 0.020”). The
rapid solidification of the
skin tends to drive porosity
to the center of the section as
portrayed here.
0.500mm 0.380 mm 0.038 mm A B
(0.020 in) (0.015 in) (0.002 in)

7.1 Internal Porosity

Interior porosity can be detected by a range of techniques, including detection by fluoroscope, X-ray and
ultrasonic procedures. Internal porosity can also be detected in the die casting plant through sectioning
or simulated machining techniques, when the die caster is advised of the areas to be machined.
Part prints should call out the areas where only the lowest levels of pinpoint porosity can be
tolerated, areas where additional porosity can be tolerated and areas where larger porosity will
have no effect on the casting application.
Whether porosity levels are defined by “X-ray” or “sectioning” procedures, each party should retain
a sample radiograph or part section that defines the minimum acceptance standard (see fig. 7-17).
It is important that the user not specify porosity limits that are more stringent than required
for the application. It is also usually necessary to establish specific porosity standards indepen-
dently for each component design. The specification of special porosity detection operations
will increase the cost of the castings. 7
The type of porosity may be important in defining porosity standards. A small dispersion of
smooth, round holes (salt and pepper generally less than 1mm in diameter), which are caused
by release of disolved hydrogen or entrapped gas bubbles, may have a minimal effect on part
strength and will not tend to cause leaks. Individual, non-grouped pores are generally less
than 2mm in diameter. These types of gas porosity are those most commonly found in die
casting. See figure 7-17A through 7-17E.
In critical areas of a casting. where porosity is a concern, the acceptable porosity is often
specified in the following format:
1. The maximum allowable size of individual porosity pores.
2. The minimum allowable spacing between pores.
3. The maximum allowable density of pores in a defined area (pores/distance2)
For example a note based on this format may look like:
Porosity specification in crosshatched marked areas on print: 1mm maximum porosity pore size,
2mm minimum spacing between pores, maximum of 10 pores per 12mm 2.
More jagged-shaped shrinkage porosity, caused by solidification, can cause more problems.
This is typically a part design-related issue, and is caused by heavy sections in the casting.
Shrink porosity can be interconnected and may result in leakers. The shrink porosity does not
have to be visible to cause leakers and is often microscopic in nature. Shrinkage porosity, when
exposed, can be larger than gas porosity. For instance, a typical specification for a large drilled
and tapped boss is < 2 mm on the first three threads, < 5 mm on other threads. See figures
7-17F through 7-17H and 7-17C, as well, as subsection 7.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-13
 Quality Assurance

A B C D

E F G H

Figure 7-17: Various degrees of porosity exposed after machining.

Minimizing porosity begins with up-front planning in the design of the part and die casting die and
the management of heat in both the die and the castings. Sophisticated process control and monitoring
equipment as well as simulation software is best utilized for castings with stringent porosity requirements.
If specific porosity will be detrimental to the use of the product being cast, the die caster must
be informed of the areas that will require special control to reduce the incidence of such porosity.
This information must be supplied in detail at the time of the RFQ , so that measures such as
part design change requests, accountability for higher scrap or utilization of special processes,
can be taken in advance of die design and construction.
Since zero porosity is virtually impossible to achieve in a die casting, the size, nature and
location of permissible porosity should be identified by the customer, with the agreement of the
die caster. The user should be agreeable to accepting a specified amount of porosity in areas of the
casting where it does not impact form, fit or function. See figure 7-17.

Note: ASTM Nondestructive Testing Standard E505 provides reference radiographs for inspec-
tion of aluminum and magnesium die castings.

7.2 Parting-Line Porosity

It should be noted that some parting-line porosity may exist in some die castings. Whenever
possible, castings should be designed to avoid parting lines on complex functional or cosmetic
surfaces. Special measures will need to be taken when this cannot be done, such as adding changes
in the parting line, adding a CAM-type movement or a hand-removal operation to blend surfaces.
Parting line porosity should not be confused with parting line break-out (see figures 7-20A & B).

8 Pressure-Tight Castings

Pressure tightness (leakage) requirements for components add to die design and casting costs and
should not be specified unless required for the application.
When a pressure-tight die casting is desired, the customer should specify at the time of
quotation the pressure the die casting is expected to withstand and the relevant testing method
to be employed.
Common leak testing methods for die castings include pressurized air bubble testing (to discover
the location of the leak), gas pressure decay and mass flow testing (to determine the magnitude of
the casting leakage in pressure loss or flow rate per unit time), and helium detection probe (when
very low leak rates are required).

7-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-18A: Example radiograph of a cast-

ing with no visible porosity revealed by radi-
ography. This level of soundness is achievable
through consultation with your die caster and
good part design, process design and process
monitoring.

Figure 7-18B: Example radiograph of porosity

that does not impact part form, fit or func-
tion. The user should be agreeable to accepting
a specified amount of porosity in areas of the
casting where it does not impact form, fit, or
function.

7
Figure 7-18C: Example radiograph of shrink-
age in a thick cross-section.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-15
 Quality Assurance

When the die casting is expected to withstand specified pressures, the die caster can offer
pressure testing of a statistical sample of parts, 100% sampling or impregnating of parts to meet
the pressure specification.
If machining of the pressure-tight die casting is required, it must be recognized that
impregnation may be required after machining. The die caster should be advised of the specific
areas to be machined in advance of the die design.
The die caster will not be responsible for machining, impregnating or testing costs if the machin-
ing is done by the customer. By mutual agreement, the die caster may accept for replacement or credit
the die castings that have failed the pressure test after the machining and impregnation process.

9 Structural Quality Assurance

Structural die casting (also known as “High integrity die casting” or “High vacuum die cast-
ing”) has very different requirements on the castings and therefore also on their QA activity.
Simulations (filling, thermal, etc.) are vital for process, part and die development. It typically
uses higher purity (primary type) alloys, requires special care and technologies for melting, melt
treatment and transfer, gating, injection profile, vacuum, die spraying, etc. and it often includes
additional process steps like heat treatment. The requirements on the castings (also coming from
the way they are joined) are very different and can expose the parts to high heat (fusion weld-
ing), high impact (riveting, crash), etc. that define the alloy, process, heat treatment and other
subsequent process steps.
Along with the normal inspection requirements, the process monitoring activities is equally
critical to ensure the casting structures are closer to homogenous, with tight grain structure, free of
contaminants and detrimental oxide formations. These activities are the path to consistent mechanical
property commitments needed for safety critical components.
Normal elements like pour temperature, shot profile from slow to fast, die temperature, metal
pressures, and time cycle consistency are only part of what is needed. Ongoing degassing, die cooling
rates monitored in local die areas, vacuum levels at the cavity based on attachment strategies, shot
sleeve temperature, and conditions, spray volume, and chemistry of all lubricants potentially included
in the casting matrix. These special items are often included in the process control plan based on the
PFMEA view of the casting.
Quality gates along the entire process chain are vital for success, and part traceability from the very
beginning (to the end) is absolutely key. An example of the process and Q gates is shown in figure 7-19.
The following quality checks can be necessary in order to assure quality of structural castings:
1. Chemical analysis of metal (before casting) and adjustment, alloy modification after melt
2. H2 / density measurement
3. Careful or no fluxing as it can add contaminants to the melt chemistry; filtration after melting
4. Inclusion measurement (e.g. K-mold for continuous measurement during production,
PoDFA for process setup)
5. Measurement/control of all process parameters and recording of those for traceability
6. X ray, welding, riveting, etc. testing of the parts
7. Blister test
8. Tensile testing, other tests like bending angle, weld gas density (DI)
9. Dimensional checks and profile management after heat treatment often requiring straightening
Figure 7-19 shows the process and the places that inspection and intervention is a requirement for
these High Integrity applications. The process management as captured in the Quality activity, has
to be considered as a “System”, intertwined and rich in interactions that are often counterintuitive,
not a list of independent elements. Thinking and acting differently is necessary for success for High
Integrity applications. We don’t make changes, we look to see what has changed. Even slight shifts
can generate defects, testing failure, and ultimately safety risks to the customer.

7-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-19: High Integrity Die Casting Quality Gate (Q-Gate) Process Map

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-17
 Quality Assurance

Minor

Moderate

Major
Figure 7-20B: Parting Line Break-Out placed into
3 groups.

Figure 7-20A: Parting line porosity at various severity levels.

7-18 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-21: Example Advanced Product Quality Planning process flow chart.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-19
 Quality Assurance

Figure 7-22: Example New Project process flow chart.

7-20 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
Quality Assurance

Figure 7-23: Example New Tooling processes flow chart.

*Thanks to Twin City Die Castings for use of the example flow charts

NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021 7-21
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7-22 NADCA Standards for High Integrity and Structural Die Casting Process / Section 7 / 2021
 8
Commercial Practices section

Section Contents NADCA No. Format Page

Frequently Asked Questions (FAQ) 8-2
1 Introduction 8-2
2 Using Die Casting Specification Checklists 8-2
2.1 Defining Quality Requirements 8-3
2.2 Specifying Tolerances 8-3
2.3 General Database Guidelines 8-3
3 Die Casting Dies and Production Tooling 8-4
3.1 Die Ownership 8-4
3.2 Die Life, Maintenance, Repair and Replacement 8-5
3.3 Credit 8-7
3.4 Changes or Cancellations 8-7
3.5 Die Retention and Removal 8-7
3.6 Insurance 8-7
3.7 Gaging 8-7
3.8 First-Piece Acceptance 8-8
4 Die Cast Production Part Orders 8-8
4.1 Metal and Metal Pricing 8-8
4.2 Acceptance of Orders and Reorders 8-8
4.3 Changes, Cancellations and Errors 8-9
4.4 Credit, Payment Terms and Taxes 8-9
4.5 Packaging and Delivery 8-9
4.6 Limitations on Inspection Procedures 8-10
4.7 Compliance with Laws 8-11
5 Purchased Components 8-11
5.1 Cast-in-Place Inserts 8-11
5.2 Inventory Costs 8-11
8
6 Price Adjustments 8-11
6.1 Quotations and Metal Market Pricing 8-11
6.2 Labor and Operating Costs 8-12
7 Patent Obligations 8-13
8 Intellecual Property 8-13
9 Warranties Covering Die Castings 8-13
9.1 Extent of General Warranty 8-13
9.2 Limitations of Warranty 8-13
10 Product Liability 8-14
11 Production and Finishing Specification Checklists 8-14
Casting Production Specifications C-8-1-21 Checklist 8-15
Casting Finishing Specifications C-8-2-21 Checklist 8-16

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-1
 Commercial Practices

Frequently Asked Questions (FAQ)

1) W
 ho owns the die cast die?
See page 8-4, Die Ownership.
2) A re there checklists available that can be used for cast or finished specifications?
See pages 8-15 and 8-16 for checklists.
3) How long do dies last?
See page 8-5 and 8-6, Die Life, Maintenance, Repair and Replacement.
4) A re there any recommendations for creating CAD data files?
See page 8-3, General Database Guidelines.
5) W hat is involved with die maintenance/repair/replacement?
See page 8-5 and 8-6, Die Life, Maintenance, Repair and Replacement.

1 Introduction
In specifying die cast production, the purchase contract can be viewed as the purchase of a
comprehensive engineering service from the die caster who will use the purchaser’s tool to
convert metal to the precise form desired by the purchaser.
The die caster will usually provide other important services, such as designing, constructing
or maintaining the tool and performing machining and surface finishing operations on die cast
parts. Sub-assembly services may also be provided.
The proposal and subsequent order for die castings sets forth a contract embodying the
business practices governing a transaction in which custom engineered parts will be supplied on
a continuing basis. Quality production of a high volume of custom parts, at the most economic
level, involves a thorough understanding of the variables of the die casting process, its tooling
requirements and related trimming, secondary machining and finishing operations.
The physical properties and constants of metals and alloys used for die castings are set forth
in Alloy Data (Section 3 of this volume) and should be referred to with other accepted metal-
lurgical specifications.
Aid in determining the detailed part design requirements to be specified for cost-effective
production can be obtained from the Engineering and Design standards and guidelines in this
volume (Sections 4, 5 and 6), together with other recognized engineering data. If geometric
dimensioning is not being used on part prints, GD&T (discussed in relation to die cast parts in
Section 5) is strongly recommended for optimizing quality and lowest costs.
Tooling (Section 2) and Quality Assurance (Section 7) should likewise be reviewed well before
drawing up final product specifications.
Of equal importance to careful specification are the commercial arrangements which affect
the buying of die castings. These trade customs have evolved from industry-wide production
experience and have generally been accepted as good business practice. The commercial
arrangements are normally found in the proposal and acknowledgement forms used by the
North American die casting industry.
These specialized inter-relationships, among others, govern the ability of the custom pro-
ducer to supply die castings to specifications on prearranged quantity schedules at competitive
levels on a continuing basis. They are described in this section together with convenient die
casting product specification checklists.

2 Using Die Casting Specification Checklists

The C-8-1 Checklist (Die Cast Product Specifications) and C-8-2 Checklist (Die Cast Surface
Finishing Specifications), which appear at the end of this section, can help the purchaser to more
clearly define the die casting requirements that will impact final costs. They can serve as a production
guide to help provide accurate communication between the purchaser and the die caster, avoiding

8-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
Commercial Practices

misunderstandings later. The die caster should review these specification levels with the purchaser
to assure that the most cost-effective level is selected and, if necessary, provide samples of various
specification levels.

2.1 Defining Quality Requirements

The checklists also mention the use of SPC and other inspection requirements. It is highly desir-
able to define such requirements so there is no question about record-keeping responsibilities.
While most die casters use these techniques regularly, some purchasers have special requirements
(ie. critical features) that must be defined early in the process.
When using statistical techniques for quality control, it is important for the purchaser to
specify the parameters when requesting a price quotation. For example, general definitions of
process capability, such as Cpk, can affect tooling dimensions that are built towards one side
of the tolerance to allow for future die wear. These dimensions can vary in one direction only,
as in the outside dimensions of a cavity (see “Moving Die Components” – Section 4A). When
applying general definitions in this situation, the tool will appear to be out of limits, while it is
actually built to high quality standards for long life.
It is most important that agreement on procedures be reached prior to establishment of the quality
standards. The costs for the quality level of a feature are calculated by the die caster during the
quoting process, and any changes in standards at a later time may require a revision to the quotation.
Many of the specifications, such as the quality of a surface finish or the severity of internal
porosity, are subjective. The methods of establishing subjective standards can vary considerably, but
it is always beneficial to spend the effort required to define the standards as closely as possible.
One way of defining subjective standards is to define borderline acceptable and acceptable
samples, which should be retained as “limit” samples by the customer and the die caster. In addi-
tion, it is desirable to have pictures or a complete written description of the defects that would
cause rejection. Such provisions can be improved upon during the initial production phase.

2.2 Specifying Tolerances

It is well known that the die casting process can achieve very high dimensional precision. The
Engineering & Design Tolerance Standards for coordinate dimensioning of parts to be die
cast (Section 4A) are presented at two levels: as Standard Tolerance and as Precision Tolerance
specifications. Most die casters can improve on the Standard Tolerances, but a cost penalty in
increased cycle times will often be the trade-off.
Tolerance improvements are most directly related to part shape. If tolerance require-
ments are clearly discussed in advance with the die caster, precision tolerances can often be
maintained for a cast part with significant improvements in product performance and reduced
secondary machining and finishing operations. 8
Machining processes should also be considered well before any order for the tooling is
released. A careful evaluation of machining requirements can lead to a redesign for net-shape die
casting or near-net-shape production, with a reduced number of operations or setups.

2.3 Technical CAD Guidelines

Computer Aided Design (CAD) databases usually consist of a two-dimensional drawing (2-D)
and a three-dimensional model (3-D). To expedite communications, the die caster and cus-
tomer should be aware of each other’s CAD software capabilities early on in the project. In the
event that the die caster and customer do not utilize the same software packages, universal file
formats can be used to communicate. Although there are many available, the most common
formats are DXF or DWG (for 2-D drawings) and IGES or STEP (for 3-D models). Transla-
tion software is needed to convert files into the appropriate format.
When databases are utilized for quoting purposes, these general guidelines apply:
1. If only a 2-D drawing is provided, it should contain dimensions and general views of the part and
major features. Physical properties such as mass and part volume should be included as well.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-3
 Commercial Practices

2. If only a 3-D model is provided, the die caster should be able to retrieve dimensions and
properties from the model.
3. Secondary operations, such as machining, can be included in the database or supplied
separately.
Some general requirements when databases are being utilized for tool construction:
1. When only a 2-D drawing is provided:
1.1. Drawing should contain complete dimensions of all features.
1.2. Parting line, draft, radii, datums and tolerance (dimensional and geometric) requirements
should be clearly defined.
1.3. Secondary operations that are to be performed on the part and other requirements
should be clearly stated.
2. When only a 3-D model is provided:
2.1. All necessary draft, parting line and radii should be included in the model. Ideally the
3-D model will indicate machined surfaces.
2.2. Lines and surfaces of the model should be connected within 0.001”.
2.3. The 3-D model should be accompanied by a limited dimension part print that contains
all tolerancing information and shows any secondary machining to be performed.
An incomplete database could result in an inaccurate quote and possibly require considerable
database manipulation, which leads to additional cost and extended lead-time. The die caster and
customer should also indicate whether the 2-D drawing or the 3-D model controls the project.

3 Die Casting Dies and Production Tooling

Any die casting can be produced in a number of different ways and every die casting plant pos-
sesses different equipment and utilizes a range of production techniques. Optimum economy
and maximum efficiency for the production of any die casting, therefore, must be considered in
the light of the particular equipment with which it will be produced. The experience, technol-
ogy, skill and ingenuity of the die caster are all involved in selecting the method of production
on which the proposal is based.
Each die caster sells die casting dies, trim dies and specialized production tooling on its own indi-
vidual terms and conditions. Normally, these terms provide for an advance payment for dies with the
balance paid upon receipt of, or approval of, a sample produced from the dies and tools. Length of time
for approving parts to be 30 days if not otherwise agreed upon between die caster and customer.

3.1 Die Ownership

Generally, the purchaser of die castings will retain ownership of the die casting die, even though
the die remains with the die caster. It has also been the custom that the design and construction
of the die casting die are performed by the die caster to its own specifications, even though the
purchaser owns the die. The custom generally works to everyone’s advantage.
Die casting is a highly complex process that contains hundreds of interacting variables. Design-
ing a die for die casting operations requires understanding of the different variables involved
and how they can affect the quality of the casting. It is recommended that the die caster design
and build the die to meet the needs of the part designer, so that the die works for the die caster’s
process and machine(s).
Quality issues on a die casting can stem from die design, die construction, or production
operations. If a part designer designs and builds a die for a die caster to use in their operations it
can lead to a point of conflict if a quality issue arises during production. It is recommended that
the die caster design and build the die, but keep in contact with the part designer during the
process to provide updates and resolve any potential issues.
Consequently it is preferable for the die caster to be responsible for die design and construc-
tion. In addition to eliminating questions of responsibility, this procedure also ensures that the
die will match the casting equipment. In addition, the die caster has a vested interest in building
a high-quality die that will give few problems in production.

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Commercial Practices

The die casting die, usually owned by the purchaser, is housed and maintained at the die
caster. The die caster will be responsible for loss or damage to the die and tooling while housed at
the die caster’s facility. Some die casters offer the option of joint ownership of the die. In either
case, there are some considerations that should be addressed during the purchasing discussions.
An ownership record should be established by both parties, which will include a description
of the die and all additional components of the die. Each die should have a method of identifica-
tion, which is best done with engraving (tags can come off). Typically a number is assigned
to the die by the die caster, which is engraved on the die, slides and cores and included in the
purchaser’s record of the die.
All components purchased originally with the die should be noted in the record, such as shot
sleeves or extra slides or cores. These components usually wear out much more rapidly than the
rest of the die and they may be worn out and unavailable if the die is claimed by the purchaser.
The question of Tool Ownership as well as Replacement is often overlooked when general
discussion begins at the start of a possible new project. Since there are multiple types of tools
available for the die cast process the following descriptions for tooling and ownership is to
provide a starting point for those decisions.
New tools are generally paid for by the Customer, the Die Caster is responsible for normal
maintenance and care (as the caretaker), the customer (as the owner) for major component
replacement, full die replacement, major repairs and refurbishment. It is the responsibility of the
die caster to inform the customer of any atypical maintenance or care required. If the customer
elects not to follow the maintenance advice of the die caster the quality of the part could suffer.
In the following cases an example will be given as to typically who owns what portion of the
tool.
1) R
 apid Tooled projects frequently use a tool (mold base) that is owned by the die caster
and becomes a type of Universal Holder for Die Cavity inserts (for multiple customers).
The inserts that are used to make the part configuration are owned by the customer and
frequently will have a shorter tool life than Production made tooling.
2) For Unit Dies, the Master or Universal Holder (as above) is usually owned by the Die Caster
and the individual units and their inserts are owned by the Customer. As long as a Unit
Die is the equivalent of an Industry standard it should be able to move to a new die caster if
needed without major cost factors involved.
3) Dies by themselves are owned by the Customer and may have different shot life attached to
them based on part design and function.
Replacement is sometimes limited to the cavity inserts but could be the entire die. The die caster is
generally expected to monitor the tool condition and notify the customer that the replacement or repair
may be needed so that enough time is allowed to get the replacement funds approved and to allow the
tooling components to be approved before the original tool wears out. Sometimes, however, it is not pos- 8
sible to fully predict when a tool may need to be replaced. This can be paid for at the time of construction
of the replacement or in cases of a very high volume part an amortization account may have been set-up.
This type of account allows for a small amount to be added to the part price that will cover the cost of the
replacement when needed. It becomes the Die Caster’s responsibility to manage tool replacement and to
notify the Customer when new replacements are submitted for approval. It is important for the Customer
and Die Caster to discuss tool replacement early in the project as stricter quality requirements or difficult
geometry can lead to replacing the die sooner.
Tooling Amortization must be started at the time of the first part being produced for sale so that the
account can cover the cost of replacement start and the balance due at approval. If it is not started at
this time the tool may have to be pushed beyond normal life to pay for a new tool and to not interrupt
Customer production. This usually results in added operations to the part which can increase costs. This
process does not work with inherited tooling because of questions concerning actual shot count on the
tool but can be applied after the first replacement is completed. Either the Customer or the Die Caster
can be holder of the amortized funds for replacement but usage terms need to be clearly defined.
The Die Caster and the Customer need to agree on both the initial tool and replacement
plans (as needed) and payment terms at the start of the project so that on-going needs are met
and ownership is clear.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-5
 Commercial Practices

3.2 Die Life

The purchaser should be aware that the life of a die can be unpredictable. Die life is a function of
many factors. Among them are part design, part configuration in the die, part quality expectations,
release quantity, type of tool steel used for the die, the heat treatment of the die and the type of
alloy being die cast.
Even when the die caster makes every effort to extend die life, early failure is still possible. It
is also possible for a die to have an unpredicted very long life. An understanding of expected die
life should be discussed in the initial phases of a project.
Progressive die casters can provide tool, heat treat, and/or die surface coating/hardening
specifications developed through extensive NADCA research programs. Reports on various die
materials, heat treatments, and die surface engineering processes can be found in the NADCA
Technical Archives. Often times using non-standard material, heat treatment, or die surface
coatings/hardening can increase the cost of the die, but used in the right conditions can more
than pay for itself by increasing the life of the die. Customer and Die Caster should have
discussions about the non-standard material, heat treatment, coating or hardening to be used to
determine the expected benefits and potential risks.
When tooling is procured through a reputable die caster, tooling costs may be somewhat
higher than if a purchaser dealt directly with the tool builder. The die caster will be closely
involved in evaluations and decisions that will translate the product design into the optimum die
casting die for successful production. The increased costs almost always represent a bargain in
terms of overall costs during the life of the die.
An inexperienced purchaser who purchases tooling purely on a cost basis will find that the
costs over the life of a die are significantly higher because of a lower-quality tool, although this
will not be immediately apparent when the tool starts running. It cannot be emphasized too
strongly that good quality tooling will cost more in the beginning but pay for itself many times
over in the life of a typical die casting die.
3.2.1 Die Maintenance, Repair and Replacement
The responsibility and criteria for maintaining tooling, on the one hand, and replacing the
tooling, on the other, should be understood. In some cases, the die replacement cost is requested
to be amortized into the piece price. The most common way of structuring this portion of the
contract is for the die caster to provide minor maintenance, and the purchaser to provide major
repair and replacement.
Minor maintenance is generally described as “run-to-run” maintenance of a serviceable die to
maintain die casting production. Major maintenance would cover the replacement or rebuilding
of an entire die cavity, die section, or complex core slide that makes up a significant percentage
of the casting detail, tool steel, the coatings applied to the die, or major die resurfacing or
refurbishment. Most die casters have a preferred way of handling maintenance and it should be
made clear.
The rapid wear components should be covered in the die maintenance understanding between
the purchaser and the die caster. These components are frequently replaced by the die caster,
although each purchaser should expect to make an individual agreement for each casting. If
the components are replaced by the die caster, ownership usually remains with the die caster,
although this can vary for individual agreements.
The die caster should provide their maintenance practices to the purchaser for review. If the
purchaser has any specific expectations, such as expecting the die to be stress relieved after
a certain number of shots, they should notify the die caster so that can be included in the
maintenance schedule and cost.
Die preheating practices, gating design and die temperature control are particularly impor-
Note: Computer
tant to long die life. It is recommended that the die caster provide the purchaser with general
software is available
information about the following practices to help them understand the processes in place to
for flow simulation,
ensure long die life.
thermal and distortion
1. The die caster should provide what preheating practices are being used to extend the life of
analysis.
the die. The best results are achieved by preheating dies to a specified temperature, depend-
ing on the alloy being cast, before the first casting is made.

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Commercial Practices

2. Smooth metal flow at the correct velocities from a carefully designed gate is important to
reduce the die erosion at the gate, as well as having a significant effect on casting quality.
Die erosion can be repaired by welding, but the onset of welding significantly reduces the
ultimate life of the die.
3. The die caster should be able to discuss the use of good die design practices with the
purchaser. A die caster using trial and error without calculations for gating will have many
more problems with die erosion and part quality than one who uses calculation techniques
developed by NADCA or other authorities.
4. Die temperature control, involving careful cooling line control and proper cooling line
placement, will influence casting cycle time and have an important effect on casting quality.

3.3 Credit
The die caster generally reserves the right to change his terms of payment if a change in the customer’s
financial condition requires it. Such changes are usually requested in writing and, when necessary, may
require the die caster to stop design and/or construction pending agreement.

3.4 Changes or Cancellations

If any changes are required by the purchaser to finished die casting dies or production tooling
which deviate from the original print and/or model provided for the dies and tooling at the time
of quotation, the die caster reserves the right to requote the quality, expected die life, cost and
delivery of the tooling. Any changes to the order must be agreed to by the die caster, in writing.
The die caster will usually require some payment for cancelled orders. Payment is necessary to
compensate the die caster for costs of work in process to the date of cancellation and commit-
ments made by the die caster for purchases relating to the order.

3.5 Die Retention and Removal

It is customary for the die caster to retain control and possession of die casting dies and produc-
tion tooling. Since the full cost of engineering, designing, obtaining, and maintaining the die
casting dies and production tooling is not fully reflected in the charges to the purchaser for these
items, an additional charge may be necessary for these unreimbursed costs if the die casting dies
and production tooling are removed prematurely from the die caster’s plant.
It is also customary to allow die casting dies and production tooling which have not been
used for three consecutive years for production of die castings to be scrapped following proper
notification to the purchaser by the die caster.
Rules for the accessibility of the die should be established. If the die is to be claimed by the
purchaser, it should be available after notice has been provided, and all outstanding invoices due
the die caster are paid in full. 8
3.6 Insurance
It is customary for the insurance of die casting dies and production tooling to be the responsibil-
ity of the purchaser, unless specifically agreed upon, in writing, to the contrary.
Die casters normally have liability insurance protection against fire and theft or vandalism. However,
fire insurance usually excludes tools, which do not burn, except for the clean-up costs following a fire.
Insurance should be reviewed in each case, and business interruption in case of fire may need to be
considered. Die casters will provide worker’s compensation insurance as required by law.

3.7 Gaging
Good gaging is critical to obtaining good quality parts, both during the process and at final
acceptance, and can also help reduce part cost, especially if a casting is heavily machined. It is
important that this aspect be discussed early in the project.
The die caster can be expected to furnish standard gages. The purchaser is expected to furnish any
special gages needed in the inspection process, such as those required for determining conformance to
feature and location specifications and any gages needed for functional or statistical requirements.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-7
 Commercial Practices

All gages and gaging methods should be agreed upon in advance by the purchaser and die caster,
including any need for duplicate gages. This will aid in both part function and fit, in instances where the
die casting will be mated or assembled with other parts not manufactured by the die caster.

3.8 First-Piece Acceptance

After the first die cast samples are received from a die casting die, the die caster or purchaser will
usually be required to measure the samples and verify that they meet specifications. Modifications
from the original print which have no effect on part function or appearance can be discussed at this
time to ensure that high production rates can be maintained and premature die maintenance avoided.
Procedures for handling changes in the print specifications for the die casting should be
agreed upon. Any costs and delivery delay incurred by such changes should be quoted by the die
caster immediately after they are received. Authorization for the changes should be given by the
purchaser in writing on each change order.

4 Die Cast Production Part Orders

The commercial terms of the contract items and conditions between the purchaser and the die
caster for die cast part production are discussed below. Note that the trade customs outlined
represent the historic and customary practices prevailing in the die casting industry. Contract
forms of individual die casters will vary in some details. A model of terms and consitions can be
found at www.diecastingdesign.org/terms/

4.1 Metal and Metal Pricing

Quality metal is the foundation for good castings. Even a chemical analysis does not fully define
all the metal quality specifications that are necessary for good die casting. Low-cost, low-quality
metal cannot be expected to meet all die casting requirements.
For example, when aluminum or magnesium alloy does not meet established criteria, machining
may be more difficult or surface corrosion accelerated. When zinc alloy does not meet established
criteria, mechanical properties will be progressively and seriously reduced in use with time.
Metal price is commonly established from quotations from an approved metal supplier, or
based on known industry indicators such as the daily American Metal Market, the London
Metal Exchange, Platts or other major markets. If the purchaser elects to use an industry
indicator, he may forfeit the advantage of spot metal buys at lower than market price.

4.2 Acceptance of Orders & Reorders

4.2.1 Acceptance of Orders
Proposals for the production of die castings are prepared on the basis of the specifications and
prints known at the time of estimating. Die casting proposals are, therefore, for immediate
acceptance on the basis specified. Similarly, since orders are accepted on the basis of the require-
ments known at the time of the order, changes from the original proposal on which the order is
based may result in the need for price adjustment for the parts. The die caster reserves the right
to review all orders before acceptance.
The proposal, the order and its acceptance, signed by an authorized representative of the die
caster, constitute the entire contract with the exception that, when any provisions of the order
conflict with the proposal, the proposal and acceptance always prevail. Modifications, changes,
additions, cancellations or suspensions of an order are not binding upon the die caster, unless
accepted in writing by an authorized representative of the die caster and upon terms that will
indemnify him against all loss.

8-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
Commercial Practices

4.2.2 Reorders
Reorders for die castings are covered by the same conditions as was the original order, provided
no revised proposal and acceptance has intervened. Pricing of reorders will, of course, be affected
by quantity, alloy, labor and other costs prevailing at the time the reorder is placed.

4.3 Changes, Cancellation and Errors

4.3.1 Changes or Cancellation
Any changes to the order deviating from the original basis upon which the order was accepted
must be agreed to, in writing, by the die caster. These changes may result in the adjustment
of prices. Changes could include, but are not restricted to, delivery dates, quantities, release
dates, part prints, etc.
The die caster usually will require some payment for cancelled orders. Payment is necessary to
compensate the die caster for costs of work in process to the date of cancellation and commit-
ments made by the die caster for purchases relating to the order, including dedicated equipment
specifically acquired for a cancelled project.
Any change to the delivery schedule or release dates beyond 90 days must be subject to
negotiation between the die caster and the customer.

4.3.2 Errors
Clerical errors are, of course, subject to correction regardless of whether they favor the buyer or
the seller and enforceable if discovered within a period of one year.

4.4 Credit, Payment Terms and Taxes

4.4.1 Credit
The die caster generally reserves the right to change terms of payment if changes in the customer’s
financial condition requires it. Such changes are usually requested in writing and, when necessary,
may require the die caster to stop production or suspend shipment pending agreement.

4.4.2 Terms of Payment

Each die caster sells its products on its own individual terms and conditions. Shipments are
generally FOB (or EXW) the city in which the die casting plant is located. Payment is normally
net 30 days with provision for metal market and escalation clauses.

4.4.3 Taxes and Duties 8

Sales or use taxes, excise taxes, taxes on transportation, other direct taxes and applicible duties
are the responsibility of the purchaser whether such taxes are federal, state or local.

4.5 Packaging and Delivery

4.5.1 Shipping Tolerances
Since the die caster cannot determine in advance the exact loss factor in a particular run, it is
generally recognized that he may manufacture and ship 10% over or 10% under the number of
die castings ordered or released. If no deviation is to be allowed, with pricing affected accord-
ingly, this should be so specified in the purchasing agreement.

4.5.2 Packaging
Die castings are generally packed in bulk as the most suitable and economical method. Any
special requirements, such as specifying layer packed, separated or cell-packed shipments, must
be communicated to the die caster in the RFQ ; otherwise a price change may be required later.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-9
 Commercial Practices

If recyclable packaging is required, it should be carefully spelled out in the quoting phase. While
this type of packaging can have a positive impact on pricing, it may increase up-front costs. The
die caster and customer should discuss responsibilities associated with recyclable packaging.

4.5.3 Deliveries
Unless otherwise specified, deliveries of die castings generally begin as soon as the die caster’s
schedules permit and, in the case of a new die, after approval of samples. Deliveries are made at a
rate approximately equal to the capacity of the tools until orders are completed. The purchaser selects
the method of delivery and, unless otherwise specified on the purchaser’s order, the die caster will
use his best judgement in routing the shipment and seeing that deliveries are effected as specified.
Acceptance of the goods by the carrier shall constitute a delivery. Any charges in connection with
postponement or cancellation of delivery are the responsibility of the purchaser. The purchaser will
also be responsible for any additional costs of expedited or other special transportation as result of
changes in delivery schedules not caused by die caster.
Penalties upon the die caster for delayed delivery, whatever the cause, are not normally accept-
able unless agreed upon at the time the order is being placed.
Many die casters today can provide an electronic connection to high volume purchasers to
facilitate placing orders, as well as provide bar coding. It is frequently desirable to anticipate
emergencies and provide for backup tooling, a small amount of emergency inventory or some
other way of addressing the catastrophic failure that can occur in any volume production process
based on sophisticated tooling.

4.5.4 Lot Size versus Cost

Because of the cost of setup, die casting is usually a high-volume process where the cost of a
small lot is significantly increased by setup costs. It is therefore imperative that lot sizes be
considered in the discussions of the purchasing contract. Each die caster will have his own costs
for setup, so the break-even point for minimum lot sizes will vary among die casters. Some
purchasers use consignment inventory agreements to address the reality of die setup costs and
tooling life factors that are adversely affected by the short runs.
Lot size should be considered in the early stages of determining the tooling requirements.
For example, in some cases fewer cavities on a smaller die will result in lower tooling costs,
lower setup costs and a smaller economical lot size. This may be more desirable even though the
piece-price may be slightly higher.
If small lot sizes are required often, quick setup aids, such as quick-disconnects, can be built
into the tooling. Advising the die caster of small lot requirements at the time of quotation will
enable him to optimize the use of these aids.
It is desirable for the purchaser to take time to explore the options of economical lot size,
costs of maintaining inventory and tooling options during the tooling quotation phase. Since
there may be many options, it is suggested that the purchaser provide the die caster with those
considerations that are important for the project and let the die caster propose several options.
This will allow the die caster to maximize the efficiency of the equipment available in his plant
and provide the most economical quote to the purchaser.

4.6 Limitations on Inspection Procedures

4.6.1 Prints and Approved Samples
Die castings may not be rejected because of variation from print dimensions if they are made to,
and are unchanged from, approved samples with respect to dimensions, finish and analysis. When
the purchaser has specified or approved the design, failure with regard to function or fitness for use
shall be the purchaser’s responsibility. If sample die castings have not been approved and conflict-
ing models and prints have been submitted, the basis of acceptance shall be agreed to in writing.

8-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
Commercial Practices

4.6.2 Accuracy
Die castings may not be rejected if they vary from finished sizes or dimensions within limits agreed
upon. Where a very close tolerance or particular dimensional accuracy is specified, the permissible
variations shall be agreed upon before die work is begun. In the absence of applicable standards,
tolerances will be subject to the commercial variations generally prevailing in the industry.

4.6.3 Inspection and Sampling Procedures

If specified and specifically acknowledged and agreed to by the die caster, die castings can be
inspected on the basis of statistical quality control or other sampling procedures.
Use of statistical quality control standards and other related procedures require specific
detailing by prior mutual agreement on all aspects involved.

4.7 Compliance with Laws

Die caster will comply with applicable laws, rules and regulations of the country where the
casting is made. Die caster will provide customer with material safety data sheets and, upon
request, provide other information reasonably required in order to comply with applicable
laws.

5 Purchased Components

Innovation in the design of die castings and flexibility in the industry’s manufacturing process
have led to the use of purchased components for insertion or assembly by the die caster. The
procurement and subsequent responsibilities for the delivery and quality of such components lies
with the purchaser of the die casting unless otherwise agreed upon and included in the quote
and the order. These components may be “insert cast” as an integral part of the die casting or
may be assembled to the die casting in a separate operation.

5.1 Cast-in-Place Inserts

If the finished casting contains cast-in-place inserts, the responsibility of providing them to the
proper specifications should be clearly defined. The design of the purchased component is the
responsibility of the die casting purchaser and is subject to approval by the die caster. In many
cases the clearances in the die will require that the insert tolerances be tighter than the purchaser
would normally supply for the required end use. If the purchaser is supplying the inserts, provi-
sion must be made to ensure that all supplied inserts are within tolerance. An out-of-tolerance 8
insert can seriously damage the die.

5.2 Inventory Costs

Regardless of who purchases an additional component, there must be consideration given for
in-process spoilage and rejects. As a result, the quantities of purchased components will always
exceed the number of die castings purchased. It is understood that there are costs associated with
handling, storing, counting and inspecting of purchased components. Inventory of purchased
components required to meet the die casting purchaser’s delivery schedule are the responsibil-
ity of the die casting purchaser. The labor cost for inserting or assembling the component is
normally included in the quoted piece price.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-11
 Commercial Practices

6 Price Adjustments

Because of the job-shop nature of production and the variation in product design and specifica-
tions, the prices for die castings are determined by the use of price estimating formulas.
Each die caster employs an individual pricing formula constructed in accordance with their individual
methods and costs. All price estimating formulas contain a number of factors which may require
adjustment, upward or downward, because of conditions beyond the control of the estimator. Significant
unexpected increases in the cost of either natural gas and/or electricity may result in negotiated energy
surcharges per mutual written agreement.

6.1 Quotations and Metal Market Pricing

6.1.1 Order Quotations
Order quotations for die cast products, and die casting dies and production tooling necessary to make
the die cast products, are normally valid for a fixed period of time. After this time has expired, the die
caster reserves the right to requote based upon price adjustment provisions as discussed above.
To establish a uniform basis of comparison, the estimated weight and monthly and/or yearly
quantity requirements should be specified when soliciting quotations, and it should be requested
that the material cost be itemized.

6.1.2 Metal Market Pricing

Prices for die castings are based on the die caster’s prevailing cost for the alloy specified on the
day the estimate is prepared. In some instances, the die caster’s quotation may make reference to
various published alloy prices or other indicators. The cost for the alloy is subject to fluctuation
beyond the control of either the purchaser or the die caster and the actual price charged for the
die casting will reflect the changes required to adjust for all metal market variations. Similar
adjustments may be made on each release and/or reorder.

6.2 Labor and Operating Costs

6.2.1 Labor Costs
Many die casting dies are in production over extended periods, often over many years. For
this reason, the piece-part labor cost may change over the life of the order. If piece-part labor
costs change after the date of the original price estimate, it is generally necessary to change the
piece-part price for future deliveries.
Customer schedules often are expanded and sometimes require production beyond the normal
schedules of the die caster.
Since all die casting prices are estimated on the basis of production at straight-time rates, an
adjustment is generally required if premium labor rates are necessary to meet the customer’s
expanded needs.
Die casting price estimates and quotations reflect labor costs based on continuous operation for
the quantity specified for any delivery release. Reductions in scheduled deliveries or production
interruptions by the customer, may affect labor and other piece part costs. In such cases, a price
adjustment may be necessary.

6.2.2 Operating Costs

Costs of outside services (such as painting, plating and machining), or of purchased supplies
and components (such as inserts, packing materials and fasteners), or action of governmental
or regulatory agencies may cause periodic increases in the costs of manufacturing. These added
costs must be reflected in changes to quoted prices. Also, changes in acceptance criteria by the
customer may significantly affect the die caster’s operating costs, making an adjustment to the
part price necessary.

8-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
Commercial Practices

7 Patent Obligations

Die casting is essentially a conversion process by which metal shapes are produced for a
purchaser. Therefore, if a die casting infringes, or is claimed to infringe on any letters patent or
copyright, the purchaser must assume the responsibility involved.
While the die caster does provide input into the design of the customer’s component for die
casting manufacturing feasibility, the die caster is not responsible for the design or functionality
of the customer’s product or device or for the design of the die casting as part of such product
or device. The purchaser of die castings is liable for his own product or device and for all patent
infringement claims relating to it or any of its parts.
Die casting proposal and acknowledgment forms generally include clauses which provide that
the die caster shall be indemnified and held harmless of and from all expenses arising from all
such claims. When patents, design or otherwise, are involved, they should be specifically called
to the attention of the die caster.

8 Intellectual Property

Die Caster is not required to provide any intellectual property used to produce parts for the
purchaser. Purchaser has the right to use parts in purchaser’s product.

9 Warranties Covering Die Castings

9.1 Extent of General Warranty

Die casters, like other responsible manufacturers, stand behind their product. However, it should
be understood that the die caster in assuming this proper responsibility focuses its engineering
efforts upon the die cast manufacturing feasibility of the component, rather than the compo-
nent’s product function which is the responsibility of the purchaser.
In general, die casters agree, at their option, to correct, replace or issue credit for, defective die
castings, subject to specific limitations and exceptions. Reference NADCA Terms and Condi-
tions for more details on warrenties.

9.2 Limitations on Warranty

8
9.2.1 Processing After Delivery
No warranty attaches to a die casting which has been altered, machined or finished after delivery
to the purchaser by the die caster.

9.2.2 Reasonable Time

No claim for defective die castings will be recognized unless made in writing within 90 days (or
as agreed upon between die caster and purchaser) after delivery.

9.2.3 Returns
Die castings claimed to be defective are not to be returned to the die caster without specific
approval and inspection by the die caster. Returned goods accepted by the receiving department
of the die caster are not exempted from the right of the die caster to inspect the die castings or to
determine the extent, if any, of his liability.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-13
 Commercial Practices

9.2.4 General Limitations

Losses, damages or expenses arising from the use of a die casting, or labor costs or other charges
incurred outside of the die caster’s plant, or transportation costs, as well as losses due to other
causes, are not acceptable basis for claims against die casters under the warranty provisions. The
Warranty as stated in paragraph 8.1, above, is limited to the repair or replacement of defective
die castings or the issuance of credit for their return as stated.

10 Product Liability

Die casters cannot be expected to have technical knowledge relating to the end product of the many
industries they service. While they may freely offer design services to make a product easier to
manufacture, at no time does this imply a knowledge of the strengths, stresses or other forces that
may be induced in the product’s end use. This must be exclusively the liability of the buyer and design
suggestions are offered by the die casters with this understanding.
The die casting industry has always maintained the position that a die caster is not liable for the failure
of a die casting in a buyer’s product, if the part furnished to the buyer meets the prescribed specification.
Die casters accept the responsibility of manufacturing a part to the buyer’s specifications within the
agreed acceptance level. This means the buyer will accept a percentage of parts that do not conform
to the specifications. Die casters cannot be held liable for any failure in the end product because of the
decision on the part of the buyer to perform a limited incoming inspection or to forgo an incoming
inspection altogether.
If a buyer approves a sample for production of parts that do not meet specification in any
way, this approval constitutes a change in specification and the die caster’s responsibility is then
altered to only meet this altered specification.
It is anticipated that the buyer will indemnify and defend the die caster from any damages or
claims arising from the use of die castings or other goods produced to the buyer’s specifications.

11 Production and Finishing Specification Checklists

The C-8-1 Checklist (Die Cast Production Specifications) and C-8-2 Checklist (Die Cast
Surface Finishing Specifications) appear on the following pages.
It is recommended that, prior to final quotations, and always before any die design commences,
the casting requirements defined by these checklists be reviewed with the die caster, together
with the specifications and procedures listed in Section 7, “Quality Assurance.” All of these
items impact final costs and should be thoroughly discussed to assure accurate communication
between the purchaser and the die caster.

8-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
Commercial Practices NADCA
C-8-1-21
CHECKLIST

This checklist is for use in con-

Casting Production Specifications sultation with your die caster
prior to estimating production
costs. Use in combination with
To be used in consultation with your caster (Use in combination with Checklist C-8-2)* the Finishing Checklist C-8-2.
Also review Checklists T-2-1A
and T-2-1B, for Die Casting Die
Checklist for Die, SSM and Squeeze Casting Production Part Purchasing Specification, in Section 2.

This Production Checklist provides a convenient method for assuring

important factors involved in purchasing cast parts are evaluated and No. Cost Effect
clearly communicated between the purchaser and the caster.
It should be used as a supplement to the essential dimensional and  1 Most economical basis for production
alloy specifications detailed on part prints submitted for quotation,  2 Involves additional work which may
since the listed factors directly affect the basis on which the casting affect cost
quotation is made. The checklist may be reproduced for this purpose.  3 Additional work which may increase
Your caster will clarify any item requiring further explanation. cost
This checklist provides a numbering system in which the lowest  4 Special Requirements which may
numbered description for each requirement can be met at the lowest increase cost
production cost, as follows: Part #

Casting  1 Some residue and chips not objectionable

Cleanliness  2 Shop run — blown reasonably free of chips but not degreased
A  3 Clean, dry and free of chips
 4 Special requirements ___________________
Cast Surface  1 Mechanical quality — finish is not significant
B Finish  2 Painting quality — streaks and chill areas coverable with paint
 3 Highest quality — for electroplating, decorative finishing, O-ring seats
Metal Extension  1 No die trimming — break off gates and overflows
(Flash) Removal  2 Die trimmed to _________________ of die casting surface (See NADCA Guideline G-6-5)
C Parting Line  3 Hand filed or polished — flush with die casting’s surface
External Profile  4 Customer defined requirements (such as thermal, tumble or vibratory deburring, or shot or grit blasting)
Metal Extension  1 Flash not removed
D (Flash) Removal  2 Flash trimmed ___________________ of die casting surface
Cored Holes  3 Flash to be machined or otherwise completely removed
Metal Extension  1 Not removed (See NADCA Guidelines G-6-4)
E (Flash) Removal  2 Crushed or flattened (See NADCA Guidelines G-6-4)
Ejector Pins  3 Removed from specific locations ___________________
Pressure  1 No requirement
F Tightness  2 Pressure-tight to agreed-upon psi (kPa). Testing medium: ___________________
 3 Other arrangements to be agreed upon
8
Flatness  1 No requirement
 2 To NADCA “Standard” specification tolerances (S-4A-8)
G  3 Critical requirement — to NADCA “Precision” specification tolerances (P-4A-8)
 4 Customer defined requirements
Dimensions  1 Normal: per NADCA “Standard” specification tolerances
H  2 Semi-critical: “Precision” tolerances on specified dimensions, others “Standard”
 3 Critical: Special tolerances to be agreed upon
Customer’s  1 No unusual inspection requirements — no Statistical Quality Control
I Receiving  2 Statistical quality control: Acceptable at Cpk 1.33 or higher (or AQL over ____________)
Inspection  3 Statistical quality control: Acceptable at Cpk 2.0 or higher (or AQL over_____________)
Packaging  1 Not critical — bulk packed
 2 Layer packed, with separators, or weight restriction
J  3 Packed in cell-type separators or individually wrapped
 4 Customer defined requirements ___________________ ___________________
* The specification provisions and procedures listed in Section 7, “Quality Assurance,” should also be addressed.
Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or Production Specification.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021 8-15
 NADCA Commercial Practices
C-8-2-21
CHECKLIST

This checklist is for use in con- Casting Surface Finishing Specifications

sultation with your die caster
prior to estimating production
costs. Use in combination with To be used in consultation with your caster (Use in combination with Checklist C-8-1)*
the Finishing Checklist C-8-2.
Also review Checklists T-2-1A
and T-2-1B, for Die Casting Die Checklist for Finished Die, SSM and Squeeze Casting Part Purchasing
Specification, in Section 2.
This Finishing Checklist provides a convenient method for assuring
that important factors involved in the surface finishing of cast parts are
No. Cost Effect evaluated and clearly communicated between the purchaser and the
caster.
 1 Most economical basis for production It should be used as a supplement to the essential dimensional and
 2 Involves additional work which may alloy specifications detailed on part prints submitted for quotation, since
affect cost the listed factors directly affect the basis on which the casting quotation
 3-4 Additional work which may is made. The checklist may be reproduced for this purpose. Your caster
increase cost will clarify any item requiring explanation.
 5 Most difficult surface to cast on a This checklist provides a numbering system in which the lowest
production basis numbered description for each requirement can be met at the lowest
Part # production cost, as follows:

Casting Insert  1 No insert used in cast part

K  2 Inserts required, to be supplied by customer at 10% overage
 3 Inserts required, to be supplied by caster
Parting Lines  1 Polishing not required
L  2 Polish only where marked on drawing
 3 Polish all parting lines (except as noted)
Surface  1 No buffing required
M Preparation  2 Mechanical (burnishing, tumbling, etc.) Specify: ____________________________________
 3 Buff as indicated on drawing
Plating,
 1 Protective Only — Specify: ______________________________________
Anodizing
N or Other
 2 Decorative Paint — Specify: ______________________________________
Special Finish  3 Severe Exposure Protection — Specify: ______________________________________
Painting  1 Heavy Paint, Protective Only — Specify: ______________________________________
 2 Decorative Paint — Specify: ______________________________________
O
 3 Application requires base coat or special treatment: __________________________________
Specify: ______________________________________
Environmental  1 Normal interior use only
P  2 Exposure to weather — Specify: ______________________________________
 3 Exposure to unusual chemistry — Specify: ______________________________________
As-Cast  1
Utility Grade — surface imperfections acceptable, nondecorative coatings
Surface  2
Functional Grade — slight, removable surface imperfections, heavier coatings
See NADCA  3
Commercial Grade — removable imperfections
Q Guidelines
 4
Consumer Grade — no objectionable imperfections, as agreed upon, when viewed under normal
G-6-6 lighting conditions at ___________________ feet viewing distance
 5 Superior Grade — specified average surface finish value of ______________ microinches, per print
Special For special flash removal requirements, see Checklist C-8-1, items C & E
R Requirements For special packaging/weight restrictions, see Checklist C-8-1, item J

* The specification provisions and procedures listed in Section 7, “Quality Assurance,” should also be addressed.
Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or Production Specification.

8-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 8 / 2021
 9
High Vacuum, Squeeze and Semi-Solid section
Casting Examples
Section Contents Page
1 High Vacuum Castings 9-2
Right/Left Hand Bracket 9-2
Engine Base Bracket 9-2
Composite Engine Sub-Frame 9-2
2 Squeeze Castings 9-3
Oil Pump Housing 9-3
G-Car Trailing Arm 9-3
Upper Control Arm 9-3
Pulley 9-4
Clutch Spider 9-4
Lower Control Arm 9-4
Front Steering Knuckle 9-5
Engine Mount 9-5
Rocker Arm 9-5
Differential Carrier 9-6
Shift Actuator 9-6
GQ Cylinder Head 9-6
Steering Knuckle 9-7
Rear Steering Knuckle 9-7
Rack & Pinion Steering Gear Housing 9-7
Rack & Pinion Steering Gear Housing 9-10
End Head 9-10
3 Semi-Solid Metal Castings 9-11
Multi-Link 9-11
Actuator Shaft 9-11
Lower Crank Housing 9-11
Control Arm 9-12
Fuel Rail 9-12
Upper Fork Plate 9-12
Transmission Belt Cover 9-13
Front Suspension Arm 9-13
Engine Mount 9-13
Brake Drum 9-14
Transmission Belt Cover 9-14 9
Steering Knuckle 9-14
Rear Door Hinge 9-15
Pulley 9-15
Vibration Damper Bracket 9-15
Engine Transmission Cartrdige Plate 9-16
Water Pump Housing 9-16
Multi Link Rear Suspension 9-16

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-1
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
High Vacuum Casting
Part Name: Right/Left Hand Bracket
Application: Automotive
Part Weight: 0.75 lbs.
Alloy: Aural-2
Heat Treat- T5
ment:
Special Re- —
quirements:
New Part or Converted from low pressure
Substitution: permanent mold, which required
extensive machining.
Customer: BRP Skidoo

High Vacuum Casting

Part Name: Engine Base Bracket
Application: Automotive
Part Weight: 6.2 lbs.
Alloy: ADC3SF
Heat Treat- —
ment:
Special Re- High strength, low weight,
quirements: net shape
New Part or Replaced stamped steel
Substitution: assembly (reduced compo-
nents from 16 to 1 piece)
Customer: Honda

High Vacuum Casting

Part Name: Composite Engine
Sub-Frame
Application: Automotive
Part Weight: 13.5 lbs.
Alloy: ADC3SF
Heat Treat- —
ment:
Special Re- High strength, weldable
quirements:
New Part or Replaced stamped steel
Substitution: assembly (reduced com-
ponents from 48 to 16
pieces)
Customer: Acura

9-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Squeeze Castings
Part Name: Oil Pump Housing
Application: —
Part Weight: —
Alloy: ADC-12(383)
Heat Treat- —
ment:
Special Re- Pressure tightness,
quirements: net shape
New Part or —
Substitution:
Customer: Lexus

Squeeze Castings
Part Name: G-Car Trailing Arm
Application: Automotive Trailing Arm
Part Weight: 15.5 lbs.
Alloy: —
Heat Treat- —
ment:
Special Re- High strength/low mass.
quirements:
New Part or New; consolidated a
Substitution: proposed 6 piece ferrous
weldment to a single alumi-
num casting
Customer: Oldsmobile, Buick

Squeeze Castings
Part Name: Upper Control Arm
Application: Automotive Suspension
Part Weight: 2.2 lbs.
Alloy: A356.2 Strontium 9
modified
Heat Treat- T6
ment:
Special Re- Fatigue life greater than
quirements: two piece forging
New Part or Conversion from ductile
Substitution: iron
Customer: Cadillac

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-3
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Squeeze Castings
Part Name: Pulley
Application: Automotive
Part Weight: 1.3 lbs.
Alloy: 390
Heat Treat- T6
ment:
Special Re- High integrity, light weight,
quirements: wear resistance
New Part or Replaced iron castings
Substitution:
Customer: —

Squeeze Castings
Part Name: Clutch Spider
Application: Snowmobile Clutch Spider
Part Weight: 1.1 lbs.
Alloy: 356
Heat Treat- T6
ment:
Special Re- Wear resistance
quirements:
New Part or Substituted for a high pres-
Substitution: sure die casting, results a
average life span doubled
Customer: —

Squeeze Castings
Part Name: Lower Control Arm
Application: Automotive
Part Weight: 5.1 lbs.
Alloy: A356
Heat Treat- T6
ment:
Special Re- Safety critical component-
quirements: must see strength, impact
& fatigue requirements
New Part or Conversion from D4512
Substitution: ductile cast iron
Customer: Volvo

9-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Squeeze Castings
Part Name: Front Steering Knuckle
Application: Automotive
Part Weight: 6.0 lbs.
Alloy: A356
Heat Treat- T6
ment:
Special Re- Safety critical component-
quirements: must meet strength, impact
& fatigue requirements
New Part or Conversion from D4512
Substitution: ductile cast iron
Customer: Ford

Squeeze Castings
Part Name: Engine Mount
Application: Automotive
Part Weight: 1.0 lbs.
Alloy: GS-AlSi13Fe
Heat Treat- None
ment:
Special Re- Better fatigue resistance
quirements: than conventional die
casting
New Part or New Part
Substitution:
Customer: Volkswagen/Audi

Squeeze Castings
Part Name: Rocker Arm
Application: Automotive engine valve
actuator
Part Weight: 0.2 lbs.
Alloy: AlSi12CuNiMg
Heat Treat- T6 9
ment:
Special Re- Better fatigue resistance
quirements: than conventional die
casting
New Part or New Part
Substitution:
Customer: Mercedes

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-5
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Squeeze Castings
Part Name: Differential Carrier
Application: Independent Rear Suspen-
sion
Part Weight: 16.5 lbs.
Alloy: ADC-12
Heat Treat- T6
ment:
Special Re- —
quirements:
New Part or Converted from an
Substitution: iron casting
Customer: Visteon Corporation

Squeeze Castings
Part Name: Shift Actuator
Application: Steering Column
Part Weight: 0.25 lbs.
Alloy: MKC Sweries TK
Heat Treat- —
ment:
Special Re- —
quirements:
New Part or Converted from a steel
Substitution: investment casting
Customer: Delphi Corporation

Squeeze Castings
Part Name: GQ Cylinder Head
Application: Vehicle Air Conditioner
Compressor
Part Weight: 1.37 lbs.
Alloy: A356.2
Heat Treat- —
ment:
Special Re- Leak test with gas medium.
quirements: Ports and bolt hole to be
porosity free
New Part or New Part
Substitution:
Customer: Sanden International
(USA), Inc.

9-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Squeeze Castings
Part Name: Steering Knuckle
Application: Automotive
Part Weight: 5.1 lbs.
Alloy: A356.2
Heat Treat- T6
ment:
Special Re- Maintain minimum
quirements: property levels
New Part or Substitution for traditional
Substitution: manufacturing processes
of forging and/or iron-steel
castings, resulting in lighter
weight
Customer: Jaguar Cars Ltd.

Squeeze Castings
Part Name: Rear Steering Knuckle
Application: Rear wheel and suspension
support for a high
performance sports car.
Part Weight: 5 lbs
Alloy: A356.2
Heat Treat- T6
ment:
Special Re- Pressure tightness,
quirements: net shape
New Part or Substitution for cast and
Substitution: forged iron and aluminum
Customer: Jaguar

Squeeze Castings
Part Name: Rack & Pinion Steering
Gear Housing
Application: Houses hydraulic fluid,
rack and pinion to turn the
wheels on a class 8 truck.
Part Weight:
Alloy:
8.2 lbs
ADC12
9
Heat Treat- —
ment:
Special Re- Thick walls, contain high
quirements: pressure fluid, machine to a
very fine finish, lower weight
New Part or Substitution for steel multi-
Substitution: pul part assembly
Customer: Freightliner

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-7
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Squeeze Castings
Part Name: Rack & Pinion Steering
Gear Housing
Application: Contain hydraulic fluid and
steering components for a
full size pickup truck
Part Weight: 9.2 lbs
Alloy: ADC-12
Heat Treat- T6
ment:
Special Re- Prevent distortion of rack,
quirements: high burst limit, low poros-
ity and lower weight
New Part or New Part
Substitution:
Customer: Toyota

Squeeze Castings
Part Name: End Head
Application: To transfer and direct hy-
draulic fluid through many
ports in a small area for
many tasks such as: auto
hoists, snow plows, dump
trucks, and lifts
Part Weight: 3.8 lbs.
Alloy: 380
Heat Treat- None
ment:
Special Re- Leak proof operation at
quirements: high pressures, lower
weight, reduced machining,
allow performance similar
to 6061 aluminum
New Part or Substitution for machined
Substitution: 6061 billet aluminum part
Customer: Stone Hydraulic

9-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Semi-Solid Metal Castings
Part Name: Multi-Link
Application: Rear Suspension Support
Part Weight: 15.0 lbs.
Alloy: A356
Heat Treat- T5
ment:
Special Re- Low weight, high strength
quirements:
New Part or New Part
Substitution:
Customer: Alfa Romeo

Semi-Solid Metal Castings

Part Name: Actuator Shaft
Application: Automotive Steering
Part Weight: .1 lbs.
Alloy: 356
Heat Treat- T6
ment:
Special Re- High strength, low weight
quirements:
New Part or Converted from a steel invest-
Substitution: ment casting
Customer: Porsche

Semi-Solid Metal Castings

Part Name: Lower Crank Housing
Application: Light Weight Bicycle
Part Weight: 1.1 lbs.
Alloy: A356
Heat Treat- T6
ment:
Special Re- High strength, low weight 9
quirements:
New Part or Substitution for two
Substitution: squeeze castings, elimi-
nating the joining opera-
tion. The squeeze casting
process was unable to
produce the different sec-
tion thickness
Customer: —

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-9
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Semi-Solid Metal Castings
Part Name: Control Arm
Application: Automotive Control Arm
Part Weight: .5 lbs.
Alloy: A356
Heat Treat- T6
ment:
Special Re- High strength, excellent
quirements: impact resistance, low
weight
New Part or New Part
Substitution:
Customer: Porsche

Semi-Solid Metal Castings

Part Name: Fuel Rail
Application: Automotive
Part Weight: .8 lbs.
Alloy: 356
Heat Treat- T5
ment:
Special Re- Pressue tightness, low
quirements: weight, corrosion resis-
tance
New Part or New Part
Substitution:
Customer: Visteon Powertrain
Control Systems

Semi-Solid Metal Castings

Part Name: Upper Fork Plate
Application: Motorcycle
Part Weight: 1.8 lbs.
Alloy: 357
Heat Treat- T5
ment:
Special Re- —
quirements:
New Part or Substitution of gravity pour
Substitution: aluminum
Customer: Derbi (Spain)

9-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Semi-Solid Metal Castings
Part Name: Transmission Belt Cover
Application: Automotive
Part Weight: 2.8 lbs. (assembled)
Alloy: 357
Heat Treat- T5
ment:
Special Re- Net Shape
quirements:
New Part or New Part
Substitution:
Customer: FIAT Auto

Semi-Solid Metal Castings

Part Name: Front Suspension Arm
Application: Automotive
Part Weight: 1.3 lbs.
Alloy: A356
Heat Treat- T6
ment:
Special Re- Near net shape
quirements:
New Part or Substitution of forged part
Substitution:
Customer: TRW

Semi-Solid Metal Castings

Part Name: Engine Mount
Application: Automotive
Part Weight: 1.8 lbs.
Alloy: A357
Heat Treat- T5
ment:
Special Re- Net Shape 9
quirements:
New Part or New Part
Substitution:
Customer: FIAT Auto

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-11
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Semi-Solid Metal Castings
Part Name: Brake Drum
Application: Automotive
Part Weight: 3.7 lbs.
Alloy: A390
Heat Treat- T5
ment:
Special Re- Low weight, wear resis-
quirements: tance
New Part or Substitution of cast iron
Substitution:
Customer: FIAT Research Center

Semi-Solid Metal Castings

Part Name: Transmission Belt Cover
Application: Automotive
Part Weight: 3.3lbs.
Alloy: A357
Heat Treat- T5
ment:
Special Re- Net Shape
quirements:
New Part or New Part
Substitution:
Customer: FIAT Auto

Semi-Solid Metal Castings

Part Name: Steering Knuckle
Application: Automotive
Part Weight: 4.8 lbs.
Alloy: 357
Heat Treat- T5
ment:
Special Re- Low weight, high strength
quirements:
New Part or Substitution of cast iron
Substitution:
Customer: Alfa Romeo

9-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
High Vacuum, Squeeze and Semi-Solid
Casting Examples
Semi-Solid Metal Castings
Part Name: Rear Door Hinge
Application: Audi model A2 rear door
Part Weight: 0.17 kg
Alloy: A357
Heat Treat- T6
ment:
Special Re- Low weight, net shape,
quirements: high strength
New Part or New part
Substitution:
Customer: Audi

Semi-Solid Metal Castings

Part Name: Pulley
Application: Vehicle Power Steering
Pump
Part Weight: 0.55 lbs.
Alloy: UltraliteTM metal matrix
composite
Heat Treat- None
ment:
Special Re- Light weight and wear
quirements: resistance
New Part or Substitution for ferrous
Substitution: component with compa-
rable wear resistance
Customer: Prototype, Ford (potentially others)

Semi-Solid Metal Castings

Part Name: Vibration Damper Bracket
Application: Engine Bracket
Component
Part Weight: 80 g 9
Alloy: A357
Heat Treat- T5
ment:
Special Re- Strength, hardness, near
quirements: net shape manufacturing
New Part or New Part
Substitution:
Customer: Peugot

NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021 9-13
 Heat Treatment & Temper Designations
for High Vacuum, Squeeze & SSM Casting
Semi-Solid Metal Castings
Part Name: Engine Transmission Car-
tridge Plate
Application: Non-automotive
Part Weight: 440 g
Alloy: A357
Heat Treat- T5
ment:
Special Re- Light weight, high strength
quirements:
New Part or Substitution of cast iron
Substitution:
Customer: —

Semi-Solid Metal Castings

Part Name: Water Pump Housing
Application: Non-automotive
Part Weight: 135 g
Alloy: A357
Heat Treat- T5
ment:
Special Re- Light weight
quirements:
New Part or Substitution
Substitution:
Customer: —

Semi-Solid Metal Castings

Part Name: Multi Link Rear Suspension
Application: Daimler Chrysler Pacifica
Automobile
Part Weight: 3.3 lbs.
Alloy: 356
Heat Treat- T6
ment:
Special Re- —
quirements:
New Part or Conversion from aluminum
Substitution: forgings
Customer: Daimler Chrysler

9-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 9 / 2021
Glossary

This glossary of terms is presented to

aid the product designer and specifier in Alloy, primary
communicating with the custom die caster
during product development and production. Any die casting alloy whose major constituent
It includes definitions involved in product has been refined directly from ore, not recycled
prototyping, the design and construction of scrap metal.
the die casting die and trim die, die casting
production and post-casting machining and
surface finishing operations. Alloy, secondary
Any die casting alloy whose major constitu-
Abrasive blasting ent is obtained from recycled scrap metal.
Nearly 95% of die castings provided in North
America are made from secondary alloys.
A process for cleaning or finishing by which
abrasive particles are directed at high velocity
against a casting or work piece.
Alloy, standard
Any die casting alloy that has been assigned an
Acid pickle
ASTM designation.
A method to remove oxides and other con-
taminants from metal surfaces.
Alloying
The process of making a die casting alloy from
Aging its various constituents. The process usually
consists of melting the major constituent and
A change in the metallurgical structure of an adding the others to the bath where they then
alloy occurring over a period of time following dissolve. The molten metal is then cleaned of
casting, which affects the properties and contamination by fluxing.
dimensions. Heating accelerates aging.

Amortization
Aging, artificial
A financial method to defer tooling cost and
A low temperature heat treatment meant to include the tooling cost with casting production
accelerate aging, generally applied to increase on a prorated basis. For example, if tooling life
strength and/or to stabilize properties. is agreed to be 100,000 acceptable castings and
the tooling cost is $100,000, the prorated cost is
$1.00 per each acceptable casting shipped, and
Aging, natural invoiced at shipment.

Aging that occurs at room temperature.

Anode

Alloy The electrode in a plating bath at which metal

ions are formed, negative ions are discharged
A substance having metallic properties and
composed of two or more chemical elements,
or other oxidizing reactions occur.
10
of which at least one is metal. Alloy proper-
ties are usually different from those of the Anodic metal
alloying elements.
Any metal that tends to dissolve, corrode or
oxidize in preference to another metal when
the metals are connected electrically in the
presence of an electrolyte.
NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-1
 Glossary

Anodizing steel balls, without abrasives.

To subject a metal to electrolytic action as the

anode of a cell in order to coat with a protec- Barrel burnishing
tive or decorative film.
The smoothing of surfaces by means of tumbling
a part in rotating barrels in the presence of
ANSI metallic or ceramic shot, without abrasives.

American National Standards Institute.

Barrel plating

AQL Plating in which a part is processed in bulk in

a rotating container.
Acceptable Quality Level, as agreed upon for
the fulfillment of production orders.
BHN

As-Cast Brinell Hardness Number, scale used to

indicate hardness.
Condition of a casting that has not been given
a thermal treatment subsequent to casting.
This is also termed as the “F temper.” Biscuit

Excess metal left at the end of the injection

ASQ cylinder of a cold-chamber die casting
machine, formed at the end of the plunger
American Society for Quality. stroke. Also called a slug.

ASTM Black chromium

American Society for Testing and Materials. Nonreflective, black chromium coating
electrodeposited from a sulfate-free bath.

Atmospheric corrosion
Black nickel
Surface corrosion caused by exposure in the
environment to gasses or liquids that attack Nonreflective, decorative, black nickel coating
the metal. having little protective value, produced by
electroplating or simple immersion.

Bailment
Blister
The voluntary transfer of property, such as
dies, fixtures, gages, etc., in trust by the Bailor A surface defect or eruption caused by
(customer) to the Bailee (vendor). This can be expansion of gas, usually as a result of heating
codified with a “Bailment Agreement”. trapped gas within the casting, or under metal
which has been plated on the casting.

Ball burnishing

The smoothing of surfaces by means of

tumbling parts in the presence of hardened

10-2 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Blow holes Cpk

Voids or holes in a casting that may occur due Total process capability. A production process
to entrapped air or shrinkage during solidifica- capability index of both a process dispersion
tion of heavy sections. and its central tendancy, taking into account the
spread of the distribution and where the distribu-
tion is in regard to a specification midpoint.
Bright finish

A finish with a uniform nondirectional smooth CQI

surface of high specular reflectance.
Continuous Quality Improvement, an
approach to quality management that builds
Bright nickel upon traditional quality assurance methods by
emphasizing the organization and systems. It
Decorative nickel plate that is deposited in the focuses on “process” rather than the individual;
fully bright condition. recognizes both internal and external “custom-
ers”; and, promotes the need for objective data
to analyze and improve processes.
Bright plating

A process that produces an electrodeposit Cadmium plate

having a high degree of specular reflectance
in the as-plated condition. Abrasive particles A coating of cadmium metal applied to an
are applied in liquid suspension, paste or aluminum or steel substrate for corrosion
grease stick form. protection or improved solderability. Cadmium
plate on zinc die castings requires an interme-
diate barrier layer of nickel.
Buffing

Smoothing a surface with a rotating flexible Cass test

wheel, to the surface of which fine abrasive
particles are applied in liquid suspension, paste (Copper accelerated salt spray) An accelerated
or grease-stick form. corrosion test for electroplated substrates
(ASTM 368-68).

Burnishing
Castability
The smoothing and polishing of a metal
surface by rubbing or tumbling in the presence The relative ease with which an alloy can be
of metallic or ceramic balls and in the absence cast; includes the relative ease with which it
of abrasives. flows and fills out a die/mould cavity, and its
relative resistance to hot cracking and tearing.

Butyrates
Casting rate
Organic coatings based on butyric acid
derivatives having excellent initial color and The average number of shots that can be cast 10
good resistance to weathering. during one hour of steady running.

Cp

Capability index.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-3
 Glossary

Casting section thickness Casting volume

The wall thickness of the casting. Since the The total cubic units (i.e. cu. in. or cu. mm) of
casting may not have a uniform thickness, the cast metal in the casting.
section thickness may be specified at a specific
place on the casting. Also, it is sometimes
useful to use the average, minimum or typical Cathode
wall thickness to describe a casting.
The electrode in electroplating at which
metallic ions are discharged, negative ions are
Casting yield formed or other reducing actions occur.

The weight of casting or castings divided by

the total weight of metal injected into the die, Cathode robber
expressed as a percent.
An auxiliary cathode so placed as to divert
electrical current to itself from portions of the
Casting cycle articles being plated which would otherwise
receive too high a current density.
The total number of events required to make
each casting. For die castings, the casting
cycle generally consists of solidification time, Cathodic metal
machine movement and sequencing time and
the operator’s manual movements. Any metal that does not tend to dissolve, cor-
rode or oxidize in preference to another metal
when the metals are connected electrically in
Casting drawing the presence of an electrolyte.

The engineering drawing that defines the

size, shape and tolerances of the casting. This Cavity
is a detailed drawing of the casting only and
not an assembly of the product in which the The recess in the die in which the casting
casting is included. is formed.

Casting, functional Cavity block

A die casting that serves a structural or mechani- The portion of the die casting die into which
cal purpose only. It has no decorative value. most, if not all, the cavity is formed. There are
usually at least two cavity blocks in each die set.

Casting thickness Cavity fill time

See Casting section thickness. That period of time required to fill the cavity with
metal after the metal begins to enter the cavity.

Casting, thin wall Center line shrinkage

A term used to define a casting which has Shrinkage or porosity occurring along the
the minimum wall thickness to satisfy its central thermal plane or axis of a cast part.
service function.

10-4 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Charpy Clamping force Color- Com-

ing pos-
Name of an impact test in which the speci- Actual force applied by a die casting machine ite
men, forming a simple beam, is struck by a to a die clamp to keep the die closed. This may The
hammer while resting against anvil supports be less than the clamping capacity of the die
plate
produc-
spaced 40 mm apart. casting machine. tion of An
desired electro-
colors deposit
Checking Cold chamber on metal consisting
surfaces of two
See Fatigue, thermal. The molten metal chamber of a cold-chamber, by or more
die casting machine. This is a hardened tube (shot appropri- layers
sleeve) through which the shot plunger moves to ate of metal
Chemical cleaning inject the molten metal into die. The cold chamber chemical deposited
and plunger combine to form a metal pump. It is or succes-
The removal of foreign material from a surface called the cold chamber because it is cold relative electro- sively.
by means of immersion or spraying without to the metal put into it. chemical
the use of current. action,
or light
Com-
Cold forming buffing
Chromate of metal pres-
Bending of a die casting without the applica- surfaces sive
A conversion coating consisting of trivalent tion of heat to achieve a desired shape that is for the yield
and hexavalent chromium compounds. different than that as cast. Cold forming is purpose
frequently used to hold an assembled part to of
the die casting. produc-
Chromating ing a
high
The application of a chromate coating. Cold shut luster;
also
A lapping that sometimes occurs where metal called
Chrome pickle fronts join during the formation of solidified Color
metal that sometimes occurs in the formation Buffing.
A chemical treatment for magnesium in nitric of die castings which constitutes an imperfec-
acid, sodium dichromate solution. The treatment tion on or near the surface of the casting.
gives some protection against corrosion by Com-
producing a film that is also a base for paint. bina-
Cold-Chamber machine tion
die
Chromium plate A die casting machine designed so that the
metal chamber and plunger are not continually A die
A coating of electrodeposited chromium metal immersed in molten metal. with two
which affords superior resistance to tarnishing
or more
and abrasion.
different
Color anodize cavities
each
Clamping capacity An anodic coating that is dyed before sealing
with an organic or inorganic coloring material.
produc-
ing a 10
The force a die casting machine is capable of different
applying against the platen to hold the die part, also
closed during metal injection. called a
family
die.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-5
 Glossary

strength movement each time the die is opened.

The maximum stress that a metal, subjected to

compression, can withstand without a predefined Core pin
amount of yield (normally 0.2% for die castings).
A core, usually of circular section. Core pins are
hot work tool steel pins, usually H-13, used for
Contraction a cored hole in a die casting and may be fixed or
movable. A core is made from a core pin.
The linear change typically occurring in metals
and alloys on cooling to room temperature.
Core plate
Contraction Factor
The plate to which the cores are attached and
which actuates them.
A factor used to multiply casting dimen-
sions to obtain casting die dimensions. It
accommodates differences in Coefficients of
Thermal Expansion of the die steel and alloy, Core slide
and die operating temperatures.
Any moving core.

Conversion coating
Core, fixed
A coating produced by chemical or electrochemi-
cal treatment of a metallic surface that forms a A core that, as the die opens and closes, does
superficial layer containing a compound of the not move relative to the cavity block into
metal; example: chromate coatings on zinc and which it is mounted.
cadmium, oxide coating on steel.

Core, moving
Cooling channel
A core that must move through some travel as
A tube or passage in a die casting die through the die opens or immediately after the die has
which a coolant (typically water, oil or air) is opened, to allow the unrestricted ejection of
forced to cool the die. the casting.

Copper plate
Corrodkote
A coating of copper deposited by electrolytic
or electroless plating methods. Copper electro- An accelerated corrosion test for electroplated
plated from a cyanide solution is generally used substrates (ASTM 380-65).
as the initial layer in plating zinc die castings.
Acid copper is used as a leveling deposit under
nickel-chromium plate. Corrosion

Degradation of a metal by chemical or electro-

Core chemical reaction with its environment.

A part of a die casting die that forms an internal

feature of the casting (usually a feature with Corrosion endurance
considerable dimensional fidelity) and is a
separate piece from the cavity block. A core may Resistance to corrosion as a function of time.
be fixed in a stationary position relative to the
cavity block or may be actuated through some

10-6 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Cover gas Deburring

A mixture consisting of sulfur hexafloride, The removal of burrs, sharp edges or fins by
carbon dioxide and air, used to protect and mechanical, chemical, electrochemical or
minimize oxide formation on the surface of electrical discharge means.
molten magnesium.

Decorative finish
Cover; cover die
A plated, painted or treated surface having
The stationary half of a die casting die. aesthetic qualities and the ability to maintain
those qualities in service.

Covering power
Defect
The ability of a plating solution, under a
specified set of plating conditions, to deposit Imperfections in a cast part - such as pores,
metal on the surfaces or recesses of a part, or inclusions, cracks, cold shuts, laps or the like.
in deep holes.

Deflection
Creep
The bending or twisting of a die casting or a
Plastic deformation of metals held for long tool when a load is imposed on it. Deflection
periods under stresses less than the normal is normally used to describe elastic strain (i.e.,
yield strength. the item will return to its original shape when
the load is removed) rather than permanent
(plastic) deformation.
Creep strength

The constant nominal stress that will cause a Deformation, plastic

specified amount of creep in a given time at a
constant temperature. Bending or twisting of a die casting or a tool
by a load that is beyond its elastic limits,
and the casting or tool does not return to its
Current shield original shape when the load is removed.

A nonconducting medium for altering the

current distribution on an anode or cathode. Degasifier

A substance that can be added to molten metal

Damping to remove soluble gases that might otherwise be
entrapped in the metal during solidification.
Ability of material to dampen vibration in
components and thus lower noise levels.
Degassing

DOE (1) A chemical reaction resulting to remove

10
gases from the metal. Inert gases are often
Design of Experiments used in this operation. (2) A fluxing procedure
used for aluminum alloys in which nitrogen,
chlorine, chlorine and nitrogen and chlorine
and argon are bubbled up through the metal
to remove dissolved hydrogen gases and oxides

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-7
 Glossary

from the alloy. See also flux. Die cast skin

The metal on the surface of a die casting, to

Degreasing a depth of approximately 0.020 in. (0.8 mm),
characterized by fine grain structure and
The removal of grease and oils from a surface. freedom from porosity.

Dendrite Die casting

A crystal that has a tree-like branching pattern A process in which molten metal is injected
most evident in cast metals slowly cooled at high velocity and pressure into a mold (die)
through the solidification range. cavity.

Deoxidizing Die halves

(1) The removal of oxygen from molten metals A die casting die is made in two parts, the
through the use of a suitable deoxydizer. (2) cover and the ejector. These are called the
Sometimes refers to the removal of undesirable “halves” of the die.
elements other than oxygen through the
introduction of elements or compounds that
readily react with them. (3) In metal finishing, Die insert
the removal of oxide films from metal surfaces
by chemical or electrochemical reaction. A removable liner or part of a die body.

Dichromate process Die life

A chemical treatment for aluminum, magne- (1) The number of usable castings that can be
sium and zinc alloys in a boiling dichromate made from a die before it must be replaced
solution, resulting in a surface film that or extensively repaired. (2) The distance,
resists corrosion. in inches or millimeters, measured in the
direction of the trimming action that a die
cast trimming die is fitted to the casting.
Die As trim dies are repeatedly sharpened, die
life distance is reduced. When the die life is
A metal block used in the die casting process, completely sharpened off, the die steels must
incorporating the cavity or cavities that form be replaced.
the component, the molten metal distribution
system and means for cooling and ejecting
the casting. Die release

Die coating to improve casting surface quality

Die block and facilitate removal from die.

The large block of steel that forms the base

for one half of a die casting die. All other Die or steel safe
components of the die are attached to or
mounted on the die block. A technique employed in close-tolerance die
casting in which exterior surfaces of the cast-
ing are deliberately made slightly under size,
and interior surfaces slightly over size. After
a trial casting run, all dimensions are brought

10-8 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

within specified tolerances. This technique tolerance is specified for weight saving or for
ensures that all final die modifications, no manufacturing economy, and is not essential
matter how slight, are made by removing, for the product’s function.
rather than adding, metal.

Dimension, linear

Die temperature Any dimension to features of the die casting

that are formed in the same die component
A die casting die has a very complex pattern (half). Any straight line dimension on a part
of temperatures across its parting surface and of die print.
through its thickness. The expression “die
temperatures” is usually used to mean die
surface temperatures. Dimension, nominal

The size of the dimension to which the toler-

Die temperature control ance is applied. For example, if a dimension is
2.00 ±0.02, the 2.00 is the nominal dimension
The use of thermocouples in the die casting and the ±0.02 is the tolerance.
die to regulate flow rate of the cooling fluid
through the die, keeping die temperature
within preset range. Dimension, parting line

A dimension on a casting, or in a die casting

Die weight die cavity, that is parallel to the direction of
die pull and crosses the die parting line.
The mass (weight) of a die. The weight is
stamped on the die so individuals handling it
can select the proper lifting equipment. Dimensional stability

Ability of an alloy to retain its size and shape

Die, miniature unchanged with time.

Die casting dies for making die castings that

weigh less than two ounces (55 grams) are Discontinuity
usually considered to be miniature die casting
dies. Any interruption in the normal physical
structure or configuration of a part, such as
cracks, laps, seams, inclusions or porosity. A
Die, multiple-cavity discontinuity may or may not affect the utility
of the part.
A die having more than one casting cavity.

Dolomite
Die, single cavity
A mineral made up of calcium and magnesium
A die casting die that has only one cavity. carbonate.
10
Dimension, critical Double-Layer nickel

A dimension on a part that must be held An electroplated, double-layer nickel coating,

within the specified tolerance for the part of which the bottom layer is semi-bright nickel
to function in its application. A noncritical containing less that 0.005% sulfur and the top

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-9
 Glossary

layer is bright nickel containing more than Ejector marks

0.04% sulfur; the thickness of the bottom layer
is not less than 60% of the total nickel thickness, Marks left on castings by ejector pins, fre-
except on steel where it is not less than 75%. quently including a light collar of flash formed
around the ejector pin.

Dowel pin
Ejector pin
A guide to ensure registry between two
die sections. A pin actuated to force the casting out of the
die cavity and off the cores.

Draft allowance
Ejector plate
The maximum angle of the draft that is
allowed by the casting’s specification. Plate to which the ejector pins are attached
and which actuates them.

Draft
Ejector; ejector die
The taper given to cores and other parts of the
die cavity to permit easy removal of the casting. The movable half of a die casting die contain-
ing the ejector pins.

Drag-Out
Electrolyte
The solution that adheres to the objects
removed from cleaning and plating baths. A substance, usually liquid, in which the conduc-
tion of electricity is accompanied by chemical
decomposition. An electrolyte is one of the factors
Dross required for electrolytic corrosion to occur.

Metal oxides in or on the surface of molten metal.

Electromotive series

Dull finish A list of elements arranged according to their

standard electrode potential.
A finish virtually lacking both diffuse and
specular reflectance.
Electroplate

Eject An adherent metallic coating applied by

electrodeposition on a substrate for the
To push the solidified casting out of the cavity purpose of improving the surface properties.
of the die casting die.

Electropolishing
Ejection, accelerated
The improvement in surface finish of a metal
A system, usually within the die casting die, effected by making it anodic in an appropriate
that causes selected ejector pins to move faster solution.
and further than the others during the final
portion of the ejection travel. Also called
Secondary Ejection.

10-10 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Elongation FMEA

Amount of permanent extension in the vicinity Failure Mode and Effect Analysis
of the fracture in a tensile test, usually expressed
as a percentage of original gage length.
FEA

Engraved finishes See Finite element analysis.

Designs etched on die cavity surfaces by

chemical dissolution to produce specified Fatigue
patterns in the as-cast part.
The phenomenon leading to fracture under
repeated or fluctuating stresses that have a
Entrained air maximum value less than the tensile strength
of the material.
Air or other gases that are mixed with the
flowing molten metal as the die cavity is filling.
Fatigue, thermal

Epoxies The cracking (or crazing) of the die cast die

cavity surface. This is caused by the expansion
Organic coatings applied to parts, having and contraction of the cavity surface which
superior corrosion resistance and adhesion. happens every time molten metal is injected
into the die.

Erosion
Feedback
A damaged condition in the die cavity or die
runners caused by the impingement of the A process control principle in which informa-
molten metal during injection. tion about the actual performance of a
machine, tool, die or process is inputted into
the machine control system for the purpose of
Expansion, thermal coefficient of possible machine adjustments to correct any
inaccurate variable.
A numerical value of the unit change in length
of a substance with each degree of temperature
change. These values are arrived at by experi-
mentation and are tabulated in reference books. Feeding

The process of supplying molten metal to the

Extractor die cavity to compensate for volume shrinkage
while the cast part is solidifying.
In die casting, a mechanical apparatus that
enters the space between the two halves of
the opened die casting die, grips the cast shot, Ferric nitrate treatment
pulls it free from the ejector pins and removes
it from the die space.
10
Process for producing a bright, corrosion-resis-
tant finish on magnesium.

FAIR

First Article Inspection Report

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-11
 Glossary

Fillet performed on the part.

Curved juncture of two surfaces; e.g., walls

that would otherwise meet at a sharp corner. Flash (metal extension)

The thin web or fin of metal on a casting

Fin occurring at die partings, air vents, and around
movable cores. The excess metal is due to the
See Flash. working pressure and operating clearances in
the die.

Finish machining
Flash, clearance
(1) The last machining operation on the
cavity of a die casting die before the hand In die casting dies, spaces deliberately pro-
work (benching or polishing) is started. (2) vided between parts of the die for the forma-
Machining operations on a part that has been tion of flash. In trim dies and other secondary
die cast to bring the part to final specified tooling, spaces provided for the positioning of
tolerances, where die casting to net-shape was the casting flash.
not economically feasible.

Flash, trimmed
Finish
The excess material that has been trimmed
The smoothness of the surface of a die casting from a die casting that will be remelted and
or a die casting die cavity. The finish quality of a used over again.
cavity surface may be specified as the grit size to
be used in the final polishing, microinch RMS
value or SPI/SPE finish standard number. Flow lines

Marks appearing on the surface of a casting

Finite element analysis that indicates the manner of metal flow.

A numerical simulation procedure that can

be used to obtain solutions to a large class of Flow pattern
engineering problems including stress analysis,
fluid flow, heat transfer and many more. The pattern with which the molten metal
progressively fills the cavity of a die casting die.

Fit
Flow rate
The preciseness or accuracy with which two
parts must be fitted together. The clearance or The volume per unit time of molten metal
interference between two interconnected parts. entering a cavity in a die casting die. Flow
When a die casting must be made to unusually rates are expressed in cubic inches or cubic
close tolerances to achieve a specified fit, it millimeters per second.
may impose a higher cost on its manufacture.

Fluid bed coating

Fixture
A process in which the metal to be coated is
Any apparatus that holds a part, such as a heated and inserted into the powdered resin
die casting, firmly in a predetermined posi- which is fluidized in air.
tion while secondary operations are being

10-12 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Fluidity Gage

Having fluidlike properties. In die casting: the A fixture or apparatus that checks the dimen-
distance the molten metal will travel through a sional accuracy of a produced part such as a die
channel before it freezes, at a given temperature. casting. A gage performs no work on the part.

Gaging
Flux
The process of using a gage to determine if a
A substance such as halide salts used to part is dimensionally usable.
protect and minimize oxide formation on the
surface of molten metal. Also used to refine
scrap metals. Galling

Tearing out of particles from a metal surface

Form by sliding friction.

The shape of a die casting.

Galvanic corrosion

Corrosion associated with the current of a

galvanic cell consisting of two dissimilar
Forming, cold
conductors in an electrolyte or two similar
conductors in dissimilar electrolytes.
Any of several processes in which a die casting
is reshaped by a tool or fixture, usually in a
power press, without the application of heat.
Spinning, which generates some localized Gas, trapped
heat, is still considered a cold forming
operation. Heat staking, which utilizes heated A defect in a die casting where gases (such
punches, is not a cold forming operation. as air, steam, hydrogen and gases from the
decomposition of the parting material) have
become entrapped within the casting and have
formed one or more voids.
Fracture test

Breaking a specimen and examining the

fractured surfaces to determine such things Gate erosion
as composition, grain size, soundness or
presence of defects. Die damage induced by the long term high-
temperature and high-velocity metal stream
from the die inlet gate(s).
Freezing range

That temperature range between liquidus and Gate runner

solidus temperatures in which molten and solid
constituents coexist. The runner in a die casting die that is directly
adjacent to the gate. The transition from gate
opening to runner cross-section.
10
GD&T

Geometric Dimensioning and Tolerancing Gate

(1) The passage connecting a runner or

overflow with a die cavity. (2) The entire

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-13
 Glossary

ejected content of a die, including the casting Grain

or castings and the gates, runners, sprue (or
biscuit) and flash. A region within a solidified metal where the
crystalline structure of the atoms is relatively
perfect. The entire structure of the metal is
Gate, center made up of such grains. During cooling the
grains are formed by growing larger from
A gating arrangement in a die casting die that chance joining of atom pairs or from an
causes the injected metal to enter the cavity impurity. As the grains grow they meet each
from the center of the part instead of along an other and the crystalline structure ends at
outer edge. The casting must be open in the these boundaries.
center, like a wheel or bezel, to be center gated.

Grain refinement
Gating system
The manipulation of the solidification process
The passages, except the cavity, in a die casting to cause more (and therefore smaller) grains
die through which the injected metal must flow. to be formed and/or to cause the grains to
The gating system includes the sprue or biscuit, form in specific shapes. The term “refinement”
main runner, branch runners (if any), gate is usually used to mean a chemical addition
runners, approach, the gate, overflows and vents. to the metal, but can refer to control of the
cooling rate.

Geometric characteristics
Grain structure
Geometric characteristics refer to the basic
elements or building blocks which form the The size and shape of the grains in a metal.
language of geometric dimensioning and
tolerancing. Generally, the term refers to all
the symbols used in form, orientation, profile, Grit blasting
runout and location tolerancing.
Abrasive blasting with small irregular pieces of
ferrous or ceramic material.
Globular microstructure
A microstructure in which the primary phase Growth
is globular, rather than dendritic. This is the
typical microstructure for semi-solid castings (1) Volumetric increase of a casting as a result
after heating to the semi-solid forming of aging, intergranular corrosion or both. (2)
temperature. See also degenerate dendrites. Growth is the opposite of shrinkage.

Gooseneck Hard anodizing

In hot-chamber die casting, a spout connect- A variation of the sulfuric acid anodizing process
ing a metal pot or chamber with a nozzle or using lower temperatures and higher voltages.
sprue hole in the die and containing a passage
through which molten metal is forced on its
way to the die. Hard buffing

Procedure for cutting down rough surfaces

using buffs made with a high thread count and
an aggressive compound.

10-14 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Hard chromium Hole, cored

Chromium that is plated for engineering In a die casting, any hole that is formed by
rather than decorative applications, and is not a core in the die casting die. A cored hole is
necessarily harder. It provides a wear-resistant distinguished from a hole that is added after
surface and can be used to salvage worn or the casting has been made (as by drilling).
undersized parts.

Hot-chamber machine
Hard spots
A die casting machine designed with the metal
Dense inclusions in a casting that are harder chamber and plunger, or metal pump, continu-
than the surrounding metal. ally immersed in molten metal, to achieve
higher cycling rates.

Hardware finish
Hot cracking
An especially smooth, as-cast surface requir-
ing no polishing and little buffing in prepara- A rupture occurring in a casting at or just
tion for plating. below the solidifying temperature by a pulling
apart of the soft metal, caused by internal
thermal contraction stress.
Heat checking

See Fatigue, thermal. Hot short

Brittle or lacking strength at elevated

Heat sink temperatures.

(1) Feature of a die casting die designed to

remove heat from the die or from a specific Hot shortness
region within the die. Water channels are the
most common type of heat sink. However, A tendency for some alloys to separate along
high thermal conductivity materials are also grain boundaries when stressed or deformed
used. (2) A die casting designed to function as at temperatures near the melting point. Hot
a heat sink in an assembly. shortness is caused by a low melting constitu-
ent, often present only in minute amounts,
that is segregated at grain boundaries.
Heat transfer coefficient

The rate a material will transfer heat energy Hot tear

per unit time through a distance due to a
temperature difference. The heat transfer A fracture formed in a metal during solidifica-
coefficients for different materials are given tion because of hindered contraction. Compare
in Btu/hr-ft-°F and W/m-°C. Also called the with hot crack.
Coefficient of Thermal Conductivity.

ISIR 10
Hiding power
Initial Sample Inspection Report
The ability of a paint to hide or obscure a sur-
face to which it has been uniformly applied.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-15
 Glossary

Impact strength Insert

Ability to absorb shock/energy, as measured by A piece of solid material, usually metal,

a suitable testing machine. that becomes an integral part of the casting.
Inserts are commonly set in the die so that
metal is cast around that portion left exposed
Impression in the die cavity. Alternatively, inserts are
often applied subsequent to casting. (Note:
(1) A cavity in a die. (2) The mark or recess left inserts become a part of the casting, whereas
by the ball or penetrator of a hardness tester. die inserts are a part of the die.)

Inclusions Intergranular corrosion

Particles of foreign material in a metallic A type of corrosion that preferentially attacks

matrix. The particles are usually compounds the grain boundaries of a metal or alloy,
(such as oxides, sulfides or silicates), but may resulting in deep penetration.
be of any substance that is foreign to (and
essentially insoluble in) the matrix.
Izod

Ingate Name of an impact test and testing machine in

which the specimen is clamped at one end only
The passage or aperture connecting a runner and acts as a cantilever beam when struck by
with a die cavity. the hammer.

Ingot Jewelry finish

A pig or slab of metal or alloy. The highest-quality, defect-free, electroplated

decorative finish for a die cast part.

Injection
Knock-Out; loose piece
The act or process of forcing molten metal
into a die. A core positioned by, but not fastened to,
a die and so arranged as to be ejected with
the casting. The knock-out is subsequently
Injection profile removed and used repeatedly.

The preprogrammed change in speed with

time of the injection ram. Speed is often Lacquer
changed during the injection stroke to mini-
mize air entrapment and die filling time. A coating composition which is based on
synthetic thermoplastic film-forming material
dissolved in organic solvent and which dries
primarily by solvent evaporation.

10-16 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Laminated object manufacturing (LOM) Hot-metal delivery results in considerable

energy and dross savings since the metal does
A method of rapid prototyping for producing a not have to be remelted at the die casting
prototype part which uses CAD data to posi- plant. Metal may be transported in the molten
tion a laser beam over a sheet of heat-activated, state for several hundred miles.
adhesive-coated paper, bonding each layer on
top of the last.
MHD Casting

Leveling electroplate Magneto-Hydro Dynamic casting is a casting

process in which the metal is vigorously stirred
An electroplate that produces a surface by a magnetic field during solidification.
smoother than the substrate.

Microthrowing power
Logo (logotype)
The ability of a plating solution or specified
A symbol used to identify a company, often set of plating conditions to deposit metal in
cast into a die cast part. fissures, pores or scratches.

Lot size Moving core mechanism

The number of pieces made with one die and The parts of a die casting die that hold and
machine setup. move a moving core. These may include gibs,
locking wedge, angled pins, dogleg cams,
racks, pinions and/or hydraulic cylinders.
Metal distribution ratio
NADCA
The ratio of the thickness of metal upon two
specified areas of a cathode.
North American Die Casting Association, con-
solidation of the Society of Die Casting Engineers
and the American Die Casting Institute.

Metal extension (flash)

NADCA Product Standards
The thin web or fin of metal on a casting
occurring at die partings, air vents and
Die casting product standards originally
around movable cores. The excess metal is
published by the American Die Casting
due to the working pressure and operating
Institute, which this publication supersedes.
clearances in the die.
ADCI and SDCE (the Society of Die Casting
Engineers) merged to become NADCA, the
North American Die Casting Association.
Metal saver

A core used primarily to reduce the amount of

Net casting yield
metal in the casting and to avoid sections with 10
excessive thickness.
See Casting yield.

Metal, hot delivery of

The practice of transferring molten metal from

the smelting plant to the die casting plant.
NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-17
 Glossary

Nickel plate surface in electrolysis. The combination of a

reactant with oxygen or an oxidizing agent.
A coating of nickel, deposited by electrolytic
or electroless plating methods, for decorative
purposes and corrosion resistance. It is usually Oxide coating
coated with a chromium flash plate for greater
resistance to tarnish and wear. A coating produced on a metal by chemical or
electrochemical oxidation for the purpose of
coloring or providing corrosion and
Nitric acid pickle wear resistance.

A pre-pickle for the ferric nitrate treatment of

magnesium. PPAP

Pre-Production Approval Process

Nitriding
A heat treating process for increasing the PPM, Parts per Million
surface hardness of tool steels by diffusing
nitrogen into the surface. The acceptance level for the fulfillment of a
production order based on the number of defec-
tive parts permissible per million parts shipped.
Nozzle

The outlet end of a gooseneck or the tubular Part print

fitting that joins the gooseneck to the sprue hole.
An engineering drawing (sometimes a repro-
duction of the engineering drawing) showing
Operation, secondary the part design. Usually “part print” refers to
the drawing of a die casting rather than a die,
A manufacturing operation, or step, that tool or machine.
is performed on, or to, a die casting after
the casting is produced but before it is
shipped to the customer or assembled Parting face
into the finished product.
The surface of a die casting die half that closes
against a mating surface on the opposite die
Overflow half. See Surface, parting.

A recess in a die, connected to a die cavity by a

gate, remote from the entrance gate (ingate). Parting line

The junction between the cover and ejector

Overflow gate portions of the die or mold. Also, the mark left
on the casting at this die joint.
A passage or aperture connecting a die cavity
to an overflow.
Parting line, stepped

A condition on a die casting where the parting

line changes abruptly from one level to another.
Oxidation

A reaction in which electrons are removed from a

reactant, as in the formation of ions at the anode

10-18 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Passive stirring Plunger

Another process for producing the feed mate- Combination of tip and rod that forces metal
rial for semi-solid casting. The liquid metal is into the die.
forced through restrictive channels as it cools,
breaking up the dendrites.
Polishing

Phosphate coating The smoothing of a metal surface by means

of the action of abrasive particles attached by
A conversion coating applied to metal surfaces adhesive to the surface of wheels or endless
for the purpose of improving paint adhesion belts usually driven at a high speed.
and corrosion protection.

Porosity
Phosphoric acid pickle
Voids or pores, commonly resulting from
A treatment to remove surface segregation solidification shrinkage; air (primarily the
from magnesium die castings and improve nitrogen component of air) trapped in a casting
corrosion resistance. or hydrogen exuded during electroplating.

Pickling Porosity dispersion

Removing surface oxides by chemical or The degree to which the porosity is spread
electrochemical reaction. throughout the casting, as opposed to being all
in one place.

Pin
Porosity, internal
A core, usually of circular section, normally
having some taper (draft). Also, a dowel (or guide Porosity that is completely encased within the
pin) to ensure registry between two die sections. die casting.

Pitting Porosity, surface

The appearance of small depressions or cavities Porosity in a die casting that is open to the
produced during solidification or as a result of surface of the casting.
corrosion and cavitation.

Port
Platen
Opening through which molten metal enters
Portion of a casting machine against which die the injection cylinder of a hot-chamber
sections are fastened, or of trim presses against machine or is ladled into the injection cylinder
which trim dies are fastened. of a cold-chamber machine.
10
Plating rack Pouring hole/slot
A frame for suspending parts and carrying Port through which molten metal is ladled into
current to articles during plating operations. the cold-chamber of a die casting machine.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-19
 Glossary

Powder coating Quench, water

This method involves electrostatically spraying The cooling of a die casting from its ejection
a premixed granulated powder onto a workpiece temperature to room temperature (or to nearly
and then curing at an elevated temperature to room temperature) by placing it in water.
obtain final coating properties. Powder coating
has many advantages, including the absence
of organic solvents, a wide choice of coating Quick-Change
materials for many service conditions, minimal
material waste, and easy handling. (1) Any construction for a tooling component
that allows the component to be replaced
without removing the tool or die from the
Preheating machine in which it is operated. (2) Die
casting die features and procedures, such as
The process of heating a die casting die prior preheating, which enable dies to be changed
to making castings to minimize the thermal on die casting machines with a minimum of
shock from the first few castings. Also applies interrupted production. Such features usually
to die heating prior to die placement in the add cost to the original construction of the
machine, for more rapid die changing and tool or die, but can save considerable machine
onset of production. downtime costs.

Press, trimming R&R

A power press (either mechanical or hydraulic) Repeatability and Reproducibility.

used to trim the flash, runners and overflows
from die cast parts after casting.
Radiograph

Pressure tightness A picture produced on a sensitive surface, as a

photographic plate, by electromagnetic radia-
A measure of the integrity of a die casting tion of wavelength less than 500 angstrom
in which a fluid under pressure will not pass units. The most common is the X-ray. X-ray
through the casting. The method of testing pictures of die castings can often reveal flaws
and the pressure used must be specified. inside the castings.

Process capabilities Radius

The range, or variation, of critical casting A convex arc blending two surfaces on a die
quality parameters (such as dimensional casting or on the model from which a die
tolerances) within which a particular die and casting is to be made. See Fillet.
machine combination will operate.

Quench Rapid prototyping

The cooling of a die casting from its ejection Production of a full-scale model of a proposed
temperature to room temperature. design more quickly and inexpensively than by
traditional methods like single-cavity proto-
type die casting, gravity casting or machining.
See also: Stereolithography, Selective laser
sintering, Laminated object manufacturing.

10-20 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Reclaim Robber

The process of smelting trimmings, scrapped See Cathode robber.

parts, dross and machine turnings back to
original alloy specifications.
Runaround scrap

Refine See Remelt.

In magnesium melting practice, the removal

of magnesium oxide and other suspended Runner
non-metallic matter by use of flux that prefer-
entially wets the impurities and carries them A die passage connecting the sprue hole or
to the bottom of the pot as sludge. plunger hole of a die to the gate or gates where
molten metal enters the cavity or cavities.

Reflective defect
Salt fog test
A casting surface defect that “reflects” an
undesirable surface condition of the die cavity An accelerated corrosion test in which speci-
steel. For example, fatigue or heating checking mens are exposed to a fine mist of a solution
of the die steel may manifest itself as cracks usually containing sodium chloride.
and craters in the steel. This will leave raised
features on the casting that “reflect” the die
surface condition. Satin finish

A surface finish that behaves as a diffuse

Release agent reflector, which is lustrous but not mirror-like.

A material that is applied to the surface of the

die cavity to keep the casting from sticking to the Scale
die. Such materials are usually applied frequently,
sometimes every cycle, and are usually applied by A build-up of material that forms on the die
spraying. To facilitate the spraying, the material cavity surface during the operation of the die
is mixed with water or a mineral solvent which casting die. The build-up material is usually a
evaporates from the cavity surface. combination of the oxide of the metal being cast
and the parting material. The scale leaves an
imprint on the casting and in extreme instances
Remelt can even change dimensions on the casting.

Sprues, gates, runners and as-cast defective

castings returned directly to the melting pot. SDCE

Society of Die Casting Engineers, which

Rheocasting merged with the American Die Casting
Institute to become the North American Die
Another term for semi-solid metal casting. Casting Association (NADCA).
10
Rib Sealed chrome pickle

A wall normal to a second wall or surface to A treatment for magnesium consisting of

strengthen or brace the second wall or surface. a chrome pickle, followed by sealing in a
dichromate solution.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-21
 Glossary

Sealing of anodic coating (2) improving resistance to stress corrosion by

producing a compressive stress.
A process which, by absorption, chemical reac-
tion or other mechanism, increases the resistance
of an anodic coating to staining and corrosion, Shot size
improves the durability of colors produced in the
coating or imparts other desirable properties. The cubic volume of a die cast shot or the
cubic volume of die casting alloy that a die
casting machine is capable of injecting into
Section, heavy a die. Shot sizes are sometimes expressed in
weight or mass units.
Any place in a die casting where the thickness
is significantly greater than (at least double)
that of the majority of the casting. Shrink mark

A surface depression, often called a shadow

Segregation mark, that sometimes occurs at a thick section
that cools more slowly than adjacent sections.
Non-uniform distribution of alloying ele- Also known as a sink.
ments, impurities, or microstructures.

Shrinkage factor
Selective laser sintering (SLS)
See Contraction factor.
A method of rapid prototyping which uses a
modulated laser beam on specialized powders to
transform CAD data into full size prototypes in
polycarbonate, nylon, or investment wax.
Shrinkage pits

A condition on a die casting where the

Semi-bright nickel solidification shrinkage has resulted in small
holes on the surface of the casting. These
Nickel plate, containing less than 0.005% holes are sometimes called “heat holes.”
sulfur, that requires polishing to give full When they form along the gate, they are
brightness or is used as-plated for the bottom called “gate holes.”
layer in a double-layer nickel plate.

Shrinkage, internal
Shield
Condition during the solidification of a casting
A nonconducting medium for altering current where volumetric shrinkage results in the
distribution on an anode or cathode. formation of a void inside the casting.

Shot Shrinkage, solidification

Die filling or part of the casting cycle in which Volume reduction that accompanies the freez-
molten metal is forced into the die. ing (solidification) of metal in passing from the
molten to the solid state.

Shot peening

The procedure of impacting a metal surface

with a high-velocity stream of metal shot or
glass beads for the purpose of (1) cleaning or

10-22 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

SIMA Solution heat treatment

(Strain Induced, Melt Activated) A wrought Heating an alloy to a suitable temperature,

process for producing feed material for semi- holding at that temperature long enough to
solid metal casting. The metal is generally hot allow one or more constituents to enter into
extruded and cold drawn. solid solution and then cooling rapidly enough
to hold the constituents in solution.

Skin
SPC, statistical process control
See Die cast skin.
Statistical techniques to measure and analyze the
extent a process deviates from a set standard.
Sleeve, shot

The molten metal chamber of a cold- Sprue

chamber die casting machine. This is a
hardened steel tube through which the shot Metal that fills the conical passage (sprue hole)
plunger moves to inject the molten metal that connects the nozzle or hot chamber to
into the die. See Cold chamber. the runners of a hot-chamber machine. (Most
cold-chamber machines form a biscuit and
have no sprue.)
Slide

Portion of a die generally arranged to move Sprue pin

parallel to the parting line. The inner end
forms a part of the die cavity wall and some- A tapered pin with rounded end projecting
times includes a core or cores. into a sprue hole and acting as a core to keep
the casting in the ejector portion of the die.

Slug Sputter coating

See Biscuit.
The formation of a deposit by the condensa-
tion of atoms or particles formed by ejection
from a surface subjected to high-energy ion
SMED bombardment.
Single minute exchange of dies, a technique
from Lean Manufacturing disciplines to SQC, statistical quality control
reduce die set up times.
Statistical techniques to measure and improve
the quality of a given process.
Soldering

The sticking or adhering of molten metal to Staking

portions of the die following casting.
A cold forming operation to a die casting.
Staking is usually performed in a power press
10
Solidification shrinkage to bend tabs or swage heads onto studs.

See Shrinkage, solidification.

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-23
 Glossary

Stereolithography T&T

A method of rapid prototyping which converts Taper and Tolerance.

3-D CAD data into a series of very thin slices
and uses a laser-generated ultravioliet light
beam to trace each layer onto the surface of a TQM
vat of liquid poly-mer, forming and harden-
ing each layer until the complete, full-size Total Quality Management.
prototype is formed.

Unit system
Strength, ultimate tensile
A die casting die built to a standardized
The maximum tensile (pulling) stress a metal design and dimensions. Also, a series of units,
can stand before rupturing. for a variety of castings, that are installed and
run in the die holder as the need for various
castings dictates.
Strength, yield

The stress at which a material exhibits a speci- Vacuum

fied limiting permanent strain or permanent
deformation. A space completely devoid of matter, even
gases. Shrinkage voids in a die casting can
be a vacuum. It is not necessary for a void to
include entrapped air.
Stress corrosion cracking

Cracking due to the combined effects of stress Vacuum assist

and corrosion. Usually this type of failure
occurs as a fine hairline crack that propagates The action of voiding the die casting die of
across the section without any exterior sign of gasses during or prior to the flow of molten
corrosion. metal to form the casting.

Stress Vent

Force per unit area. When a stress is applied to A thin narrow passage that permits air to escape
a body (within its elastic limit) a corresponding from the die cavity as it is filled with metal.
strain (i.e., change in shape) is produced, and
the ratio of strain to stress is a characteristic
constant of the body. Vibratory finishing

A process for deburring and finishing

mechanically by means of abrasive media in a
Stress, thermal container subjected to high-rate oscillations.

Stress induced into a material when a

temperature change causes a force trying to Void
change the size or shape of the part, but the
part is restrained and cannot re-spond to the A large pore or hole within the wall of a casting
thermally induced force. usually caused by solidification shrinkage or gas
trapped in the casting. Also, a blow hole.

10-24 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
Glossary

Water line

See Cooling Channel.

Wet blasting

A process for cleaning or finishing by means of

a slurry of abrasive in water, directed at high
velocity against the parts being processed.

Wire brushing

The method of burr removal, edge blending

and surface finishing by contacting the work
surface with a variety of rotating wire brushes.

Yield

See Casting yield.

ZA

A designation followed by a number, which

is used to designate a group of three zinc
based casting alloys. The number indicates the
approximate nominal aluminum content.

Zamak
An acronym for zinc, aluminum, magnesium
and copper, used to designate the zinc alloys
2, 3, 5 and 7.

10

NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021 10-25
 Glossary

10-26 NADCA Standards for High Integrity and Structural Die Casting Process / Section 10 / 2021
 NADCA Standards for High Integrity
and Structural Die Casting Process

NADCA Standards for High Integrity and Structural Die Casting Process
2021
8th Edition

3250 N. Arlington Heights Rd., Ste. 101

Arlington Heights, IL 60004
tel: 847.279.0001 • fax: 847.279.0002
publications@diecasting.org
www.diecasting.org
2021

NADCA Publication #403