Discover more about Die Casting and Its Advantages

Die Casting 101: Learn More About its Process and Advantages

One of the productive metal casting and versatile processes is precision die casting. It is distinguished by the help of a mold cavity to put in high pressure on the molten metal. The feature of the die casting process helps to design die casting parts. To meet the requirements of the process in die casting. 

Die Casting Definition

Die casting is a procedure in which the molten metal is introduced into the mold cavity. At a growing pressure up to 30,000 psi. Die casting is a highly fruitful method of casting parts with low dimensions. High surface quality, and tolerance. Die castings are produced with nonferrous metals. Such as zinc, tin-based alloys, and aluminum. The type of metal that is being cast identifies the machine type being used. Whether cold chamber or hot chamber to make the cast. It is a manufacturing process that is perfect for high-volume items. The incremental cost per item becomes very low. As metal dies and casting equipment has a large part of capital costs. The process of die casting is cheap, efficient and provides a wide range of components and shapes. It is no longer required for more shaping or tooling.

All die casting process types are created to cast a mold using injected molten metal. It depends on the part geometry and part size, type of melted metal. And various die casting processes can provide excellent outcomes over alternative methods. The main types of die casting processes are: hot-chamber and cold-chamber die casting. These two types of die casting vary including:

-Vacuum die casting

-Low-pressure die casting

-Squeeze die casting

-Semi-solid die casting

Types of Die Casting Processes

  • The Hot Chamber Die Casting Process
  • It is sometimes called hot casting, or gooseneck casting. It is the most well-known process of die casting. In this procedure, the cylinder chamber of the injection apparatus is fully submerged. In the molten metal bath. A gooseneck metal feed method takes out the molten metal into the die cavity. While straight immersion in the molten bath. Permits for convenient and quick mold injection. This also affects increased corrosion vulnerability. With this, the hot-chamber die casting method is fit for applications. They use metals with high fluidity and melting points.  
  • The Cold-Chamber Die Casting Process
  • The process of cold-chamber die casting is the same as hot-chamber die casting. It has a design that prioritizes lessening machine corrosion instead of production efficiency. The melted metal is hand ladled into the injection system. This removes the need for the injection mechanism to be absorbed in the molten metal bath. 

Learn about the Advantages of Die Casting

  • Dimensional stability and accuracy- Die casting makes dimensionally stable parts. And that is durable while sustaining close tolerances. This die casting produces heat resistance. 
  • Strength and weight- die-cast parts are powerful compared to the plastic injection. Molding with the same dimensions, the thin wall castings are lighter and stronger. Unlike the other casting methods. The strength is that of the alloy rather than the combining process. 
  • High-speed production- die castings give multiplex shapes within closer tolerances. Compared to other huge production processes. Small or no machining is needed and it can produce thousands of identical castings. Before extra tooling is required. 
  • Simplified Assembly- Die castings offer integral fastening components. Such as studs and bosses. Holes can be produced and cored to tap drill sizes. Or they can cast external threads. 
  • Many finishing techniques- die cast parts can be manufactured. With texture or smooth surfaces. They are easily done or plated with the least surface preparation.  

 

  • The Casting of low fluidity metals
  • Eliminates or reduces secondary machining operations

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