Die Casting Process and Advantages

Update:Dec 24 2016
Summary:

Have you ever wondered how some of the most common elem […]

Have you ever wondered how some of the most common elements of your favorite everyday items (like cars) are made? They are usually created in a process called "die casting." It is a process where metal is molded into a required shape. It's a rather simple (but intense) procedure that is often taken for granted in our use of the products made through die casting.

The process, which is also described as "metal casting.", is completed by forcing liquid metal into a mold under extremely high pressures. The molds are usually made of steel and come in two pieces. They are shaped and work comparable to injection molds. Most of these die casts consist of aluminum and zinc.

Basically, die casting make use of steel molds called dies where molten metal is enforced hooked on with tremendously high-pressure. Die casting is a resourceful technique that allows for a range of stages of intricacy in manufacturing from steel sinks to tiny toy cars. At the same time it still maintains complete exactitude to generate an unblemished end product.

Die Casting Process

In die casting there are four steps involved and each phase must be completed thoroughly before getting on to the next phase as it allows perfection in the end product. The die worker must be certain that the die casting machine is at the required temperature. There are several possibilities for it to get wrong if the die is cold when the molten metal is injected because it will solidify too quickly without conforming to the correct shape. Only after the die reaches the right temperature the casting should begin because heating will take plenty of time according to the size of the designed cast.

The very first step in die casting

The mold is sprayed with lubricant and then closed. Lubricating helps to regulate the temperature inside of the die, at the same time it also allows helps in trouble-free removal of the cast.

Secondly, the molten metal is injected into the die and then the metal is inserted at an enormously high pressure, thereby it allows the metal to conform to the fixed figure of the die, devoid of the risks of puffiness or air pockets inside the product.

After that you should cool the mold and thereby the metal gets solidified. It differs according to the level of the stage. The mold is immersed or sprayed with cold water to ease the casting turn out solid but, this happens in some cases only. Still the high-pressure is maintained inside the mold such that metal doesn't change properties. Finally the die opened and the solid cast removed.

Advantages:

1) Excellent dimensional accuracy

2) Reduces or eliminates secondary machining operations.

3) Rapid production rates.

4) Using die casting we can make products with pore-free products that do not allow gas to pass through them and making them strong.

5) Identical castings can be mass-produced in thousands before you are required to add any new casting tools.

Like die casting plastic injection molding is also an important process in the engineering industry and through this small and complex parts are produced with accuracy.