2012 NADCA Die Casting Design Competition - Magnesium Die Casting over 0.5 lbs.
Alloy: AZ91
Industry: Homeland Security/Defense
Main Enclosure Casting: The customer desired that internal pins be as cast, rather than a separate piece.
Using an internal lift, TCDC was able to cast internal heat sink pins as part of the casting. The alternate method was to cast a separate piece and fasten it to the casting - which would have added cost and would not have had as good of heat sink properties. The large center opening allowed both a lift and a center gated casting to aid fill on fins and pins. Minimum draft on all features help to keep the weight under design limits.
• Cast a one piece housing with external ribs as heat sinks.
• Center gating allows optimal fill.
• Minimal draft on ribs (1 deg / side), and thin wall design reduces weight.
Top Plate Casting: Deep internal bosses on the cover with Minimum draft made casting almost equal in surface area between the inside and out. The solution was to apply a double ejector system to both the Ejector half and cover half cavities.
Design Properties: The Top Plate required additional ribs to help meet heat sink properties needed. Both the Main Enclosure and Top Plate have limited draft of 1 degree per side on fins as well as thin wall design to minimize weight.
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