Die casting

Die casting

Die casting is the process of forcing molten metal under high pressure into the cavities of steel moulds. The moulds are called dies. Dies range in complexity to produce any non-ferrous metal parts (that need not be as strong, hard or heat-resistant as steel) from sink faucets to engine blocks (including hardware, component parts of machinery, toy cars, etc). In fact, the process lends itself to making any metal part that:

• must be precise (dimensions plus or minus as little as 50 µm--over short distances),
• must have a very smooth surface that can be bright plated without prior polishing and buffing,
• has very thin sections (like sheet metal--as little as 1.2 mm),
• must be produced much more economically than parts primarily machined (multicavity die casting moulds operating at high speed are much more productive than machine tools or even stamping presses),
• must be very flexible in design; a single die casting may have all the features of a complex assembly.

Difference between hold chamber and cold chamber pressure

What is the difference between hot chamber and cold chamber process ?

The plunger and cylinder are permanently submerged in the molten metal in the holding furnace in the hot-chamber die casting process, whereas a cold chamber machine the metal is ladled after each shot cycle, either manually or automatically, into the injection cylinder. So the contact between the molten metal and the machine parts (cylinder and plunger) is limited only for a short period of time.

Die casting process

This is picture of die casting machine.

die-casting

die-casting process by which molten metal is forced by a plunger or compressed air into a metallic die and the pressure maintained until the metal has solidified. Die castings are accurate, are sharply outlined, have a good surface finish, and can be made in complicated designs. Zinc, aluminum, and magnesium alloys are the principal metals used. The high cost of the die usually limits the process to large-scale, high-speed production. Typical products are carburetor bodies and zippers. Type-casting machines are specialized die-casting machines.

Die Casting Machines Importance

What is die casting machines? Sure, you have heard about it but do you really know what it is? It is a process that uses fluid that is injected into a mold at very high pressures. Probably the most popular type of this type of casting is that which is used to make model, toy cars. For example, Matchbox cars are widely known as they are made from this process.

The processing time for most castings of this type is between one and two months. Production rates can be anywhere from 20 to 200 units per hour. The machinery used in the process is huge, heavy and expensive. They work at very high pressures of upwards of 100 megapascals or higher. The main materials that are cast ten to be copper based alloys, zinc based, magnesium based or aluminum based.

Die Casting Machines

Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

Die castings machines are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.