This, as well as other fundamentals, will be covered in the following article.
Die casting is one of the most cost-effective and time-efficient forming processes available. The advantages of this manufacturing process include the ability to produce hundreds of thousands of castings in a relatively short period of time by using a single mold. All of the components that are produced are of consistent quality and have relatively low unit costs. But what does the manufacturing process look like in its entirety? Can you tell me what materials can be used, and what areas the castings are used in?
Die Casting is defined as the process of casting metal into molds
Die casting is an automated casting process in which a liquid melt is pressed into a mold under high pressure (150 to 1200 bar) and at a high filling speed (up to 540 km/h), resulting in a finished part with high strength and durability. The majority of the time, alloys with a low melting point are employed. It is particularly well suited for series and mass production of components, as opposed to other casting processes such as sand casting, because it makes use of permanent metal molds that do not need to be destroyed after the casting process is completed. It is possible to fabricate large and complex components with thin wall thicknesses using this technique.
A cavity is formed in the die casting molds by the joining of two halves of high-quality, heat-resistant steel grades, into which the liquid melt is pressed during the casting process. The halves are mounted on a stationary and a movable machine plate, respectively. High pressure is applied to the mold halves during the casting process, which is why the mold has latches to secure the mold halves together. Aside from that, specific parts of the mold are cooled and/or heated in order to ensure that the casting solidifies as desired. Mold production is extremely expensive and time-consuming, but even a single mold can produce several tens of thousands to over a million castings, depending on the complexity of the design. Another advantage of using reusable casting molds is that the melt cools down much faster than with traditional molds.
Nonferrous metals are used in die casting to manufacture components, and the alloy selected for a particular application is determined by a number of factors including budget, weight, and material properties.
Aluminum is one of the most important materials, accounting for more than 80 percent of total production, followed by zinc and magnesium. Copper, lead, and tin, on the other hand, are all acceptable materials. The alloys have a variety of different characteristics. Aluminum (600°C) and magnesium (520°C) are examples of materials with high melting points, while zinc (380°C) and lead (320°C) are examples of materials with low melting points.