Die casting is a process in which molten
metal is forced under high pressure into mold cavities. The metal
hardens to get a desired shape. In recent times, plastic molded parts
have replaced die-casting, as they are cheaper and lighter than die cast
parts. Die-casting can be done using a cold chamber or hot chamber
process. Die casting is a widespread non-expendable technique in which
metal are forced into the mold cavity under high pressure. Die casting
mold that are known as dies can be used repeatedly to produce castings
in a variety of sizes, shapes and wall thickness. The mold cavities are
designed with intricate designs that enables in producing complex shapes
with accuracy, surface finish and attractiveness.
In the early
days of die casting only low-pressure injection method was used, but
today high-pressure casting techniques like squeeze casting and
semi-solid die casting
methods are used to cast more than 4500 pounds per square inch.
Initially, only tin and lead were die caste, but now magnesium, copper
and other alloys are also to cast using this highly popular process.
In
this process molten metal or other materials are forced, under high
pressure into the cavities of the steel mold. Dies are two part molds
that are made of alloy tool steel - The fixer die half and the ejector
die half. The die or mold is fabricated with the impression of the
component that is to cast.
The
molten metal is injected into the die under high pressure and high
speed, which helps in producing a casting that is smooth and precise as
the original mold. The pressure is maintained on the mold until the hot
metal solidifies. When the metal is hardened, the die is opened to
remove the casting.
Squeeze casting - A method by which molten
alloy is cast without turbulence and gas entrapment at high pressure to
yield high quality, dense, heat treatable components.
In modern
day, sophisticated die casting machines are used that ensures consistent
quality control. Every machined die-casting differs in the method in
which molten meal is poured into the die. Automations are used to
lubricate dies, pour the metal into the chamber, etc. Two processes
called the hot chamber and the cold chamber methods are used for die
casting.
Die casting is most suitable for casting medium sized
parts with complex details. Die-casting is the largest casting technique
that is used to manufacture consumer, commercial and industrial
products like automobiles, toys, parts of sink faucet, connector
housing, gears, etc. Most die castings are done from non-ferrous metals
like aluminum, magnesium, etc.
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