A process that produces complex parts of metal by using reusing molds is called die casting. This process of metal casting is characterized by forcing molten metal under very high pressure into a mold cavity. Precision die casting manufacturer usually uses non-ferrous like aluminum, copper, lead, tin, or zinc to fabricate die-cast parts. This is an efficient way to mass-produce a great variety of engineered metal parts.
Benefits of die casting:
The die casting is a manufacturing technique that employs high pressure to force molten metal into dies. There are several benefits to the die casting process. Some major benefits of die casting include:
Die casting for metal casting produces durable and uniform products.
This process can die-cast a wide range of material. It depends on the configuration of the casting machine.
- Easy assembly:
Complex fasteners or devices attachment can be involved in the just final component.
- Surface texture:
The process of die casting of any metal is capable of delivering smooth or textured part surfaces.
Types of die casting:
The two main types of die casting machines are hot-chamber and cold-chamber. The casting machines, small or large, only vary fundamentally in the method used to inject molten metal into the die-cast. These are classified according to the properties of metal and type of molding.
- Hot-chamber casting machines:
The hot-chamber machines have a pressure chamber connected to the mold activity directly. This allows the continuous flow of molten metal into the pressured compartment. Primarily, hot-chamber machines are used for zinc and alloys of low melting points that do not attack and erode readily metal pots, plungers, and cylinders. Advancement in technologies and development allows higher temperature materials to extend the use of equipment for magnesium alloys. These machines are rapid in operation. Generally faster than the cold-chamber process of die casting.
- Cold-chamber casting machines:
The cold-chamber die casting machine requires molten metal to the hand-ladled or ladled automatically into the chamber. Through a port slot, the molten metal is poured into a cold chamber. Subsequently, an operator plunger hydraulically seals off the pressure compartment and forces the metal into the die mold. This machine is used for high melting point casting alloys as plunger and cylinder assemblies are less subject to attack. As they are not submerged in molten metals. Col-chamber helps sustain sufficient pressure with casting alloy to pack the cavity solidly.
The hot-chamber and cold-chamber casting machines can be further divided into categories also. Specialized die casting machines used in applications include:
- Semi-solid molding machines:
A type of machine that creates semi-solid metal billet effective for low porosity and heat-treatable applications.
- Squeeze casting machines:
Another method for creating low porosity and heat-treatable components is squeeze casting. This reduces gas entrapment and turbulence.
Types of die casts:
For any casting machine, die casts are a necessary component. There are four common types of die casts:
- Single-cavity die:
This type is good for creating solid and uni-body components.
- Multiple-cavity die:
This type of die can produce several identical components at once.
- Unit die:
Another type of die is useful for casting several different components simultaneously.
- Combination die:
This combination die is effective for casting numerous unique parts of metal for future assembly.