Die Casting Process and Advantages

Update:Dec 26 2016
Summary:

We introduce molten metal into the mold at high or low […]

We introduce molten metal into the mold at high or low pressure to make die casting. Earlier only low-pressure die-casting was used but nowadays high pressure die casting is used more extensively. Molds are well designed to give complex products with stunning accuracy and smooth finishing. Because of the high melting point of steel, they are made of high quality steel. We can reuse these molds thousands of times. Using die casting we can make products with pore-free products that do not allow gas to pass though them and making them strong.

Die casting is an economical yet effective process of creating a broad range of shapes. It is considered that die casting surpass other manufacturing technique and it is durable and aesthetic, merging seamlessly with the other parts of the machinery of which it is a component. Die has many advantages and primary among them is its ability to deliver complex shapes with high levels of tolerance than any other mass production methods. If you need to add any new casting tools, identical castings can be mass produced in thousands.

The aluminum in its molten form is injected with a casting machine under extreme force, speed and pressure into a steel or mold to make high pressure die for the desired shape and design. The rating of casting machines is in clamping tons universally. This rating reflects the amount of pressure exerted on the die. The size of the machine ranges from 400 to 4000 tons.

In pressure die casting, precision made dies of intricate multipart design and therefore very expensive are used, and exposed to severe working conditions, by high pressures and high successive variations in temperature. For the production of zinc and zinc alloy castings the dies may be made of unalloyed steel, however for magnesium, aluminum, copper and the alloys of these metals, the dies are generally made of hot-work steel, which has much greater durability.

Advantages:

1) Excellent dimensional accuracy

2) Get desired shape easily

3) Rapid production rates.

4) Less operation processes and lower wastage of materials

You can use die casting when dimensionally stable and durable parts are in need. They are heat resistant and maintain good tolerance levels which are crucial pre-requisites for any good machinery parts. They are stronger and lighter than parts made by other casting methods. They do not have parts that are welded or bolted together, thereby immensely enhancing their efficacy. You can achieve with casting as the surfaces can either be smooth or textured providing ease of application and use.