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Reap the Major Benefits of Die Casting

02.17.2020 · Posted in Manufacturing Articles

Under high pressure into mold cavities, die casting is a process in which molten metal is forced. To get the desired shape, the metal hardens. As they are lighter and cheaper than die-cast parts, plastic molded parts have replaced die-casting in recent times.

Using a hot chamber or cold chamber process, Die-casting of lighting die casting part can be done.

Die Casting Process

Metal is forced into the mold cavity under high pressure and Die casting is a widespread non-expendable technique. To produce castings in a variety of wall thicknesses, shapes, and sizes, Die casting mold that is known as dies can be repeatedly used.

With intricate designs, the mold cavities are designed enabling in producing complex shapes with attractiveness, surface finish, and accuracy.

History of Die Casting

The only low-pressure injection method was used in the early days of die casting, but today high-pressure casting techniques like semi-solid die casting and squeeze casting methods are used to cast more than 4500 pounds per square inch.

Initially, only lead and tin were died caste, but now other alloys, copper and magnesium, are also to cast using this highly popular process.

Die Casting Process

Under high pressure into the cavities of the steel mold, molten metal or other materials are forced in this process. Made of alloy tool steel, dies are two-part molds. The ejector dies half and the fixer dies half. With the impression of the component that is to cast, the mold or die is fabricated. There are four types of dies:

  • To manufacture one component, a single cavity is used.
  • To produce several identical parts, multiple cavity.
  • To produce different parts, the Unit die is used at one time.
  • To produce several different parts for an assembly, Combinations die.

Helping in producing a casting of furniture die casting part that is precise and smooth as the original mold, the molten metal is injected into the die under high speed and high pressure. Until the hot metal solidifies, the pressure is maintained on the mold. To remove the casting, the die is opened when the metal is hardened.

Used to produce castings for specific applications, there are several variations on the basic process. These include:

  • Squeeze casting – to yield heat treatable, dense, high-quality components at high pressure a method by which molten alloy is cast without gas and turbulence entrapment.
  • Semi-solid molding – It is a procedure were to provide heat treatable and dense castings, semi-solid metal billets are cast with low porosity.

Alloys used

In die-casting, tin, copper, Aluminum, zinc, and lead-based alloys are predominantly used.

Applications

For casting medium-sized lighting to die casting part with complex details, Die casting is most suitable. Used to manufacture industrial, commercial and consumer products like toys, automobiles, gears, connector housing, parts of the sink faucet, etc die-casting is the largest casting technique.

Benefits

  • For a wide range of complex application, Economical process that can be used.
  • Post machining can be eliminated.
  • Parts have close tolerance, dimensional accuracy, and longer service life.
  • Mold can be repeatedly used.
  • A process can be automated fully.

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