Introduction• Die casting is the Metal forming process in which molten metal

is forced into a cavity or mold under high pressure. This takes place under high pressure which is applied to the molten metal which is inserted into mold cavity.

• Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique.

Process• Die casting provides complex shapes within closer tolerances

than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.

• Die casting is one of the most versatile and prolific metalworking processes, creating countless varieties of parts used in almost every industry imaginable. Interestingly enough, it dates back to the mid 1800’s, and today, innovations keep it moving forward.

Die Casting Parts

The Hot Chamber Die Casting Process

Hot chamber die casting is one of the twomain techniques in the manufacturingprocess of die casting, Hot chamber diecasting has the advantage of a very high rateof productivity. During industrialmanufacture by this process one of thedisadvantages is that the setup requires thatcritical parts of the mechanical apparatus,(such as the plunger), must be continuouslysubmersed in molten material.

The Vacuum Die Casting Process

Vacuum casting creates goodconditions for decisively reducing gasporosity, since air is evacuated from the die cavity. Depending on the alloy used, the required values may be achieved invacuum casting even without additional heat treatment. But if such treatment is necessary, it will produce surface flaws in the presence of even minor gas porosity, which cannot be tolerated on the end product.

The Cold Chamber Die Casting Process

Cold chamber die casting is a permanentmold metal casting process. A reusable mold, gating system and all, is employed. It is most likely machined precisely from two steel blocks. Large robust machines are used to exert the great clamping force necessary to hold the two halves of the mold together against the tremendous pressures exerted during the manufacturing process.

The Low Pressure Die Casting Process

• Low pressure die casting is competitive casting method when the production quantity is relatively small and/or when heat treatment is needed to improve the mechanical properties. The tolerances and the surface finish are the same as achieved by gravity die casting. The tooling costs are somewhat higher than by sand casting.

What Are The Benefits of Die Casting?

The benefits of using die casting over other methods of part production are numerous. Die casting provides cost-effective solutions to create parts that have complex shapes, parts that require a high heat tolerance, and also allows us to produce a part with tighter and stricter tolerances. Die casting historically has inherently produced less scrap and requires less machining than machining parts our of raw billets. When compared with forgings, plastic injections, stampings, etc, die casting is the clear choice for superior part quality with a low cost. Die casting produces parts with excellent strength to weight ratios and allows for many different finishing capabilities.

Die casting machine

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