1	ARMSTRONG MOLD CORPORATION GRAPHITE DIE CASTING DIVISION
2	Getting Started The Evolution of GDC The GDC technology was developed as a hybrid of traditional permanent mold, graphite mold and the die casting process in response to ongoing demands from Engineers who were looking for a faster less expensive means of developing and testing new products. The main challenge was replicating the mechanical and physical properties of the production intent alloys and having the flexibility to make changes as the designs matured. The initial trials using A380 were carried out in1999, and further development has yielded the process as it stands today. However, given the nature of the process and the diversity of markets served it is in a constant state of development as more challenging geometries are being cast in the GDC process. It is the intention of Armstrong Mold to support further development to expand the list of alloys and methods within the scope of the Graphite Die-Casting process.
3	OBJECTIVE
4	How can it be done? Utilize an alternative mold material that produces a new level of casting CNC cavity detail to deliver production die cast tolerances Rapid solidification that ensures excellent mechanical and physical properties and cell structure. Enable processing of 380 – 390 Aluminum alloys Capable of production in excess of 50 to 100 castings per day Tooling in Days to Weeks – Not Months Provide the capability of supporting bridge to production needs
5	Process Intent The GDC process was designed for utilization for both high quality prototyping as well as low volume production applications. Prototyping Production tolerances Production like properties Quantity of parts in short time frame Ability to use parts for production machine fixture development Low Volume Production Lower capital investment for tooling Able to produce in smaller lot sizes Full machining capabilities and assembly Full finishing capabilities – painting, plating, impregnation, X-ray and pressure testing
6	General Design Data
7	General Design Data
8	MATERIAL PROPERTIES
9	MICROSTRUCTURE
10	Process Overview AVERAGE PROJECT TIME-FRAME 3D Cad Files: Customer supplied Cast & Machined, Detailed Prints (1 day) Logging in of files and data including contract review (1 day) Job launch including Tooling design review (1 day) Programming of cutter path’s (2-3 days) CNC machining of cavity, core and slides (2-4 days) CNC machining of runners and risers (1-2 days) Installation of vent posts and pins (1-2 days) Polishing of tool (1-3 days) Inspection of Cavity, Core and Slides (1 day) Assembly of tool including ejection (2-3 days) Sampling of Tooling (as cast part) (1-5 days) De-gating, Primary Grinding, Secondary Grinding (1 day ) Machining of 1^st article (3-7 days) Total 3-5 weeks
11	Prototype Parts
12	Prototype Parts
13	Production Parts
14	Production Parts Part Name: 5 parts – 2 housings, 3 covers Part Size: 4.65” x 4.76” x 1.89” Material: 390 Aluminum Quantity: 200 - 450 pcs of each part Tooling Cost: Housings- $7,600.00 each Covers- $8,550.00 each Fixturing Cost: Housing- $875.00 Covers- $1,125.00 Part Cost: Housing- $128.03 Covers - $140.58 Delivery: 3 ½ weeks ( as cast ) 4 weeks ( machined) Notes: All parts were impregnated and pressure tested @ 100psi . Parts were used as bridge to production after initial prototyping and design changes were made.
15	PROCESS COMPARISONS
16	PROCESS COMPARISONS
17	Process
18	Process
19	Process
20	Process
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22	Features of the Graphite Die Casting Process CNC cut tooling Ability to cast thin walls Flexibility for use as prototype or low volume production option Rapid solidification cycles Complete in-house mold design and construction. High part to part repeatability Castings can be used to prove out assembly fixtures, trim dies or machining fixtures.
23	Benefits of the Graphite Die Casting Process Aluminum and zinc parts in 3 - 5 weeks Semi-permanent mold will make hundreds of parts from one tool Ideal for 100-2000 parts Short run production Bridge from prototype process to production Cost effective Able to cast spec die-cast alloys-380, 390 More accurate test results for tensile, yield, hardness
24	REAL WORLD EXAMPLE
25	REAL WORLD EXAMPLE
26	Contact