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| Introduction to Die Casting |
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Die Casting Process is a metal casting process that is characterized by forcing the molten metal into a mold cavity under the application of high pressure or under gravity. Because of the metal mold, the same mold can be used for producing the infinite number of castings, hence the process is also called a Permanent Mold Casting Process. How It Works? High pressure die casting (HPDC) is a process that consists of four steps: mould preparation, filling, injection, and shake out. • Step 1: Mould Preparation: First, the mould is prepared by machining a negative image of the desired part into a block of steel. The mould can be single or multi-cavity. • Step 2: Filling: Next, the mould is filled with the molten metal. This can be done manually or automatically.• • Step 3: Injection: The molten metal is injected into the mould under high pressure. • Step 4: Shake Out: Lastly, the solidified part is removed from the mould. What Materials Are Used in Die Casting? The materials used in die casting include a wide range of alloys. Some examples include: Aluminum Aluminum alloys are by far the most important materials in volume die-cast production. They respond best to a hot chamber and high pressure—or more recently vacuum die casting—and provide moderate to high strength and high precision parts. Aluminum alloys are still critically useful in lower-tech processes, too. Zinc Zinc is very widely die-cast for many lower-strength applications. Zinc and commercial alloys it is a major constituent of are low-cost, easily cast, and sufficiently strong for many components such as enclosures, toys, etc. Magnesium Magnesium alloys are widely used for lightweight and high-strength parts. There are limitations in the processing, but magnesium alloys can achieve among the thinnest sections in die casting, because of very low viscosity in the melt. The advantages of Die Casting Process are as follows: • An economical process used for a wide range of complex applications. • A process that can be fully automated. • Post machining can be eliminated. • Parts have high dimensional accuracy, close tolerance, and longer service life. • Mold can be used repeatedly because it is made up of metal. • No external pressure is required for Gravity Die Casting Process. Disadvantages Of Die Casting: • Porosity: If the molten metal cools down too quickly in the mould, it is likely to develop a porous structure. • High Initial Investment: The cost of starting a die casting project is high. • Not Suitable For One-Offs: The fact that we have to make a custom die mould for each new casting project makes this method unsuitable for one-off productions. What Are the Applications of Die Casting? Some examples of die-casting applications are listed below: • Aerospace: A wide range of engines, seating, interior fitting, cockpit control, and other parts are die-cast in aluminum. • Toys: Many toys were formerly manufactured from die-cast zinc alloys such as ZAMAK (formerly MAZAK). This process is still widely used despite plastics taking over much of the sector. • Automotive: Many ICE and EV car parts are made by automotive die casting: major engine/motor components, gearbox/differential housings, vehicle wheels, thermostat housings, suspension parts, interior strength members, and more. • Electronics: Enclosures, heat sinks, hardware. • Military: Vehicle, weapon, and system components. • Furniture: Chair legs, decorative parts, joiners. • Consumer: Product heat-distribution chassis, enclosures, decorative and structural parts. |
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