Die Casting is a process

Die casting is a metal production technique that uses high pressure and reusable metal molds. Using die casting, metal parts with precise dimensions, well-defined contours, smooth or textured surfaces can be produced.

Details of the Die Casting Process

Simple, fast, and stable die casting is standard metal manufacturing. Here is a step-by-step guide to die casting:

The mold must be divided into two or more parts to remove the casting from the steel mold.

Using this mold, you can make hundreds of castings in a short period of time.

The part is in a fixed position after being inserted into the machine (fixed mold half). The two parts can move at the same time (injection mold half). The machine starts the casting process by clamping the two parts together.

Injecting molten metal into the mold cavity causes the metal to solidify rapidly.

When the mold halves separate, the casting is ejected.

Depending on the complexity of the casting, simple or complex molds can be created.

Die Casting is a Two-Step Process

Hot Chamber Die Casting

In hot chamber die casting, pressure is used to push hot metal into a preformed mold, just like other types of casting. However, in this process, the metal is heated in the casting machine itself, rather than in a separate furnace.

Aluminum

The following metals can be cast in a hot chamber:

Zinc

Magnesium alloys

The melting points of many other metals

Alloys that will not corrode metal pots, cylinders, or plungers can be processed in hot chamber machines.

Cold Chamber Die Casting

Despite the name, cold chamber die casting does not require hard metals. The metal is heated in a furnace separate from the casting machine, and the molten metal is then poured into the machine.

Metals with high melting points, such as aluminum, benefit from cold chamber machines.

The metal is first melted and then poured into a cold chamber to solidify.

A hydraulically driven plunger pushes the metal into a mold in the cold chamber.

Comparison of Die Casting and Sand Casting Techniques

Sand casting, like die casting, is a metal production technique that uses molten metal to fill a mold with sand. Even though each process is designed to achieve the same goal, each has its own unique characteristics.

Die casting is the fastest way to produce precision nonferrous metal parts due to the use of high pressure. When the metal cools and hardens after being removed from the mold, the die casting is complete. After that, the mold is reopened and ready for the next pour.

A new mold must be made for each casting, and sand casting does not use high pressure. Depending on the complexity of the mold, it can take hours or even days to make a new mold. Although sand casting is less expensive and requires less equipment, the process is best suited for casting smaller quantities of workpieces.

Metals and alloys used in die casting projects include stainless steel and aluminum alloys. Each alloy has its advantages and disadvantages, depending on the application.

A professional metal fabrication company can help you understand all the mechanical and physical properties and composition of various alloys. Die casting metals include the following:

Zinc

Aluminum

Magnesium

Brass, copper, lead, and tin are also used for custom die casting tasks, but more often for larger production runs.

Alloys, which are mixtures of multiple elements, can be found in metal die casting parts, but choosing the right alloy requires careful research. Since each alloy has its own unique properties, advantages, and disadvantages, planning must be done when selecting an alloy.