In the process of die casting molten metal is forced under high pressure into mold cavities. Metal gets harder to get the desired shape. In today’s times, plastic molded parts have taken the place of die-casting, as they are lighter and cheaper than die-cast parts.
Die casting part China can be done using a hot chamber or a cold chamber process.
History of Die Casting
The only low-pressure injection method was used during the early days of die casting, but today to cast more than 4500 pounds per square inch, high-pressure casting techniques like semi-solid die casting and squeeze casting methods are used. At first only tin and lead were died caste, but now using this highly popular process magnesium, copper and other alloys are also cast.
Know About Die Casting Process
Die casting is a non-expendable technique in which under the high-pressure metal is forced into the mold cavity. To produce castings in a variety of sizes, shapes and wall thickness die casting mold that is known as dies can be used repeatedly.
Process of Die Casting
In this process, molten metal or other materials are forced, under high pressure into the cavities of the steel mold. Made of alloy tool steel, Dies are two-part molds – The fixer die half and the ejector dies half. Considering the impression of the component that is to cast the die or mold is fabricated. There are four types of dies:
- To produce one component single cavity is used.
- To produce several identical parts multiple cavities are used.
- To produce different parts at a one-time unit die is considered.
- To produce several different parts for an assembly there is the use of combinations die.
Under high pressure and high speed, the molten metal is injected into the die, which helps in producing a casting that is precise and smooth as the original mold. Until the hot metal solidifies the pressure is maintained on the mold. The die is opened to remove the casting when the metal is hardened.
On the basic process, several variations can be used to produce castings for specific applications by the die casting part manufacturing. These include:
Semi-solid molding – It is a process in which semi-solid metal billets are cast to provide dense, heat treatable castings with low porosity.
Squeeze casting – To yield dense, high quality, heat treatable components, without gas entrapment and turbulence, molten alloy is cast at high pressure in this process.
Alloys used
In die-casting Aluminum, copper, lead, zinc, and tin are predominantly used.
Applications
For casting medium-sized parts with complex details die casting is the most suitable one. Die-casting is the largest casting technique that is used to manufacture commercial, consumer, and industrial products like toys, connector housing, gears, parts of the sink faucet, automobiles, etc.
Maximum die castings are done from non-ferrous metals like aluminum, magnesium, etc.
Advantages
This process is quite economical that can be used for a wide range of complex applications.
Parts have dimensional accuracy, longer service life, and close tolerance.
Total elimination of Post machining can be done.
The use of Mold can be repeatedly done.
It is a fully automated process.
