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About Die Casting

Die Casting: Introduction


Process for producing engineered metal parts by forcing molten metal under high pressure into molds, called dies.

Among the highest volume, mass produced items manufactured. Parts are important components of products ranging from automobiles to toys.

Die Casting: History


Equipment was invented in 1838 for the purpose of producing movable type for the printing industry. Development of other shapes began to increase toward the end of the century.

Die Casting: Dies


Made of alloy tool steels in at least two sections, the fixed die half and the ejector die half The cover die contains the sprue or shot hole, which allows the molten metal to flow into the dies. The ejector die contains the ejector pins and usually the runner, which is the path from the sprue or shot hole to the mold cavity.

Die Casting: Process


Injecting molten metal under high pressure into a die. Rated in clamping tons. Machine sizes range from 400 - 4000 tons. Two methods are hot chamber or cold chamber

Die Casting: Process


Four steps in traditional die casting: 1. 2. 3. 4. Die preparation Filling Ejection Shakeout

Die Casting: Process


Four steps in traditional die casting: 1. Die preparation - spraying the mold cavity with lubricant 2. Filling - molten metal is injected into the dies under high pressure

Die Casting: Process


Four steps in traditional die casting: 3. Ejection - shot is ejected by the ejector pins 4. Shakeout - separating the scrap

Process: Hot Chamber Machine


Used primarily for zinc, copper, magnesium, lead and other low melting point alloys. The injection mechanism is immersed in the molten metal bath of a metal holding furnace. The furnace is attached to the machine by a metal feed system called a gooseneck.

Process: Cold Chamber Machine


Used for alloys such as aluminum and other alloys with high melting points. The molten metal is poured into cylindrical sleeve, manually by a hand ladle or by an automatic ladle. Plunger seals the cold chamber port and forces metal into the locked die at high pressures.

Die Casting: Advantages


Excellent dimensional accuracy. Smooth cast surfaces. Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm or 0.030 in). Inserts can be cast-in. Reduces or eliminates secondary machining operations. Rapid production rates. Casting tensile strength as high as 415 megapascals (60 ksi).

Die Casting Designs


One of the first steps in designing a die cast component is choosing the proper alloy. Designers collaborate with the die caster at an early stage of the product design and development.

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