Die Casting is a process of metal casting in which molten metal is forced under high pressure into a mold cavity. The dies used in die casting are made of tool steel and have an injection mold-like shape. This allows the metal to be shaped precisely, thus producing highly accurate metal parts.
Die Casting is a complex process that requires precision molds. The weight of the material to be cast is determined by the part’s volume, wall thickness, and density. In addition, the material needed to fill the die channels must also be considered. Thinner parts typically require larger channels, while thicker ones require smaller channels. The additional material required to make thicker parts can be offset by reducing the overall volume of the part.
Hot chamber die casting uses alloys with low melting points. The process involves a fixed or movable die. The fixed die is mounted on a platen and is aligned with a gooseneck. The movable die is connected to the chamber that inserts the molten metal. The molten metal is then injected into the die with high pressure and high speed. The amount of time required to solidify the metal depends on the type of metal used.
During the die-casting process, the dies must be cleaned and prepared. They are then lubricated so that the next part can be ejected cleanly. Lubrication time may increase depending on the size, number of side-cores, and cavities. The machine will determine the amount of force needed to clamp the dies together. The metal then cools during the cooling process. In many cases, this time will vary depending on the type of metal used, and the temperature at which it solidifies. In addition, the wall thickness of the die also influences the cooling time.
After a certain time, the die halves can be opened. An ejection mechanism can then be used to push the casting out of the die cavity. The ejection time should also include the time for the casting to fall out of the die. After the ejection time, the die can be closed again, allowing for the next injection.
The melting temperature is an important factor to consider during die casting. The higher the temperature, the greater the risk of tooling failure. If the temperature is too high, the die may be unable to open. Higher temperatures will also cause the metal to lose its elasticity. This will reduce its life, resulting in an inferior quality casting.
Another advantage of die casting is that it can be produced in high volumes with minimal tooling and machining. Unlike some other processes, it is very accurate, making it perfect for complex automotive parts. This process can also produce parts with high tolerances and excellent surface finishes. However, the equipment required for die casting is expensive.
The ejection system on a die casting machine is crucial in removing excess material during the solidification process. The process takes a few minutes or a few seconds, and can be completed quickly or slowly. Aside from ejection, the die can also be fitted with overflow wells to provide extra molten metal during solidification.
A die’s frame is typically made of a thick steel plate. This machine has an insert in it that becomes an integral part of the product. The insert can be made from metal, plastic, or other alloys. During die casting, intergranular corrosion attacks the grain boundaries of the metal and causes a deep penetration.
Semi-solid die casting (also known as thixoforming) is another method used to produce parts with a high density. This method is usually used for parts made of magnesium alloys or aluminum alloys. These parts are made with low porosity and high precision. It is also very cost-effective and fast. If you want to add a decorative finish to your die-cast parts, you can consider a ceramic coating.