Processes and Advantages of Die Casting

Update:Oct 17 2016
Summary:

The use of pressure injection die-casting process can b […]

The use of pressure injection die-casting process can be traced back to the mid-1800s. The components used in the initial stage are tin and lead, but their use is tapering in with the introduction of zinc and aluminum alloys. The process has evolved over the years from low pressure injection techniques to molds capable of achieving pressures up to 4500 psi. These processes are capable of producing high quality products with excellent surface finish.

Die casting is an economical and effective process for forming a wide range of shapes. It is considered superior to other manufacturing techniques and is considered to be durable and aesthetically pleasing, and is seamlessly integrated with other parts of the machinery as part of it. Molds have many advantages, the most important of which is that they can provide complex shapes with high levels of tolerances, compared to any other mass production method. The same casting can be produced in thousands of lots before any new casting tools need to be added.

A high-pressure die is a manufacturing method in which molten aluminum is injected into a steel or die by means of a casting machine at extreme forces, speeds and pressures to produce the desired shape and designed components. Casting machine is usually rated for clamping tons. The grade reflects the amount of pressure applied to the mold. The size of the machine ranges from 400 to 4,000 tons.

The use of the casting process has many advantages over other processes. Die casting produces parts with thinner walls, closer to the size limit, and can speed up the process. Labor and finishing costs are the lowest. With this method, a complicated shape having a smaller tolerance can be easily realized. Unlike the forging process, you can project a core in a product created by this process.

The shape that can not be obtained from the bar or tubular blank can be easily realized by casting. The number of operating procedures is low, resulting in lower material waste.

When dimensionally stable and durable parts are required, die casting is used. They are heat-resistant and maintain a good tolerance level, which is a critical prerequisite for any good mechanical part. They are stronger and lighter than the parts made by other casting methods. They do not have welded or bolted together parts, which greatly enhance their effectiveness. Another advantage is the multiple finishes that can be achieved by casting. The surface may be smooth or textured to facilitate application and use.