Die Casting Process

Die-casting is similar to permanent mold

casting except that the metal is injected
into the mold under high pressure of 10-
210Mpa (1,450-30,500psi) .
Most die castings are made from non-
ferrous metals, specifically zinc, copper,
aluminium, magnesium, lead, and tin
based alloys, although ferrous metal die
castings are possible.
The die casting method is especially suited
for applications where a large quantity of
small to medium sized parts are needed
with good detail, a fine surface quality and
dimensional consistency.
Classify of Die Casting Processes:
High Pressure Die Casting:
Pressure: high to 300MPa
Pouring rate: 10~50m/s
(sometimes100m/s)
Filling time: 0.01~0.2s
Advantages : dimensional accuracy and stability
smooth surface
high strength and hardness
high efficiency
Disadvantages: unstable flow
difficult for complex castings
Two basic types of die casting machines:
hot-chamber machines (gooseneck
machines) and cold-chamber
machines.
Machine sizes range from 400 tons to
4000 tons. Regardless of their size, the
only fundamental difference in die
casting machines is the method used to
inject molten metal into a die.
Hot-chamber machines rely upon a pool of molten
metal to feed the die.
At the beginning of the cycle the piston of the
machine is retracted, which allows the molten
metal to fill the "gooseneck". The gas or oil
powered piston then forces this metal out of the
gooseneck into the die.
The advantages of this system include fast cycle
times (approximately 15 cycles a minute) and the
convenience of melting the metal in the casting
machine.
The disadvantages of this system are that high-
melting point metals cannot be utilized and
aluminium cannot be used because it picks up
some of the iron while in the molten pool. Due to
this, hot-chamber machines are primarily used
with zinc, tin, and lead based alloys.
Cold-chamber machine works by melting the
material, first, in a separate furnace.
Then a precise amount of molten metal is
transported to the cold-chamber machine
where it is fed into an unheated shot
chamber (or injection cylinder). This shot
is then driven into the die by a hydraulic
or mechanical piston.
This biggest disadvantage of this system is the
slower cycle time due to the need to transfer the
molten metal from the furnace to the cold-
chamber machine.
Cold-chamber machines are used the alloys
include aluminium, magnesium, copper, and zinc
alloys with a large composition of aluminium.
Die casting hot chamber machine
Die casting cold chamber machine
Difference of hot and cold chamber casting processes
Cold chamber
Vertical type
Entire vertical type
Horizontal type
Classify of cold-chamber machine :
Vertical type cold-chamber machine:
Match the dies Inject the molten metal Open the dies
Entire vertical type cold-chamber machine:
Open die pouring
Match the dies and
press the piston
Open the dies and
eject the casting
Horizontal type cold-chamber machine:
Match the dies Inject the molten metal Open the dies
Die-casting machine's choice :
The external dimensions of die castings is the main basis to
choose the die casting machine in clamp force.
Generally set the specific pressure of pressure-shoot P
increase
(or the largest specific pressure), then compute the
projected area F (including the gating system) of the die
castings which is perpendicular to the parting surface, the
product of them should lower than 85% of the clamp force S.
S - clamp force of the die casting machine;
0.85 - safety factor;
P - pressure per unit area affected in the molten metal during turbocharging .
0.85 SFP
increase
The weight of die castingssum of the net weight of die
castings and the gross weight of gating systemis another
basis to determine whether the capacity of die-casting
machine injection chamber could satisfy the request.
The alloy type and the gross weight are converted into
volume, and the capacity of the injection chamber should
larger it by 30%.
- the full coefficient of die chamber;
L - the effective length of die chamber, cm;
d - inner diameter of die chamber(the diameter of the injection punch head), cm;
p - the density of the casting alloy, g/cm
3
P
W
L d
2
4 4
3
or
3
2

4
3
or
3
2

4
3
or
3
2
The requirement on precision , internal
soundness(performance index) of the casting,
energy distribution during the die casting process
and other parameters are also the important
basis to choose the die casting machine.
Low Pressure Die Casting:
Pressure: 34.5~103.5.5Pa
Use: low melting point metal
heavy section
Advantages: less shrinkage
compact structure
smooth mold filling
Disadvantages: high cost
low efficiency
Gravity Die Casting:
Gravity die casting is suitable for mass
production and for fully mechanised
casting.
Vacuum Die Casting Process:
Vacuum casting process is
one of the most important
new technologies in the
future to seek.
How to operate the effective usage:
Vacuum time should be within 0.3s (maximum 0.5s). If
vacuum time is more than 0.5s, blowhole starts to increase.
20-27kPa vacuum could be obtained optimum conditions
without sealing.
Die tooling for ventilation should be designed to have
enough evacuating ability as 20-27kPa could be established
within 0.3s.
Vent runner should be adopted at the final filling point
determined by metal flow analysis. One fifth of air is
remaining after evacuate to 20kPa in the die cavity, so
remaining air should be pushed out by metal flow itself.
Calculate air
volume to be
evacuated
Assume
inspired air
volume
Calculate
vent runner
area
Calculate capacity
of required
evacuation
Vacuum Die Casting Process:
Advantages: eliminate defects like
blowhole, cold shut, flow line and misrun;
low metal pressure prolongs die life;
good parts can be easily obtained
Disadvantages: shot interferes shutting
valve when metal dreg that stuck at value
sheet
Squeeze Die Casting Process:
In the process, liquid metal is introduced into an
open die, just as in a closed die forging process.
The dies are then closed. During the final stages
of closure, the liquid is displaced into the further
parts of the die.
It especially suited for making fibre-reinforced
castings from fibre cake preform. Squeeze
casting forces liquid aluminium to infiltrate the
preform.
In comparison with non-reinforced aluminium
alloy, aluminium alloy matrix composites
manufactured by this technique can double the
fatigue strength at 300C. Hence, such
reinforcements are commonly used at the edges
of the piston head of a diesel engine where
solicitations are particularly high.
Die castings are among the highest volume,
mass-produced items manufactured by the
metalworking industry, and they can be found in
thousands of consumer, commercial and
industrial products. Die cast parts are important
components of products ranging from
automobiles to toys .
Characteristics of Die Casting Alloys
A die's life is most prominently limited by
wear or erosion, which is strongly
dependent on the temperature of the
molten metal.Aluminium alloy die usually
have a life of 100,000 cycles, if the die is
properly maintained.Molds for die casting
zinc last approximately 10 times longer
than aluminium die casting mold due to
the lower temperature of the zinc.
There are four types of dies:
1. Single cavity to
produce one
component
2. Multiple cavity to
produce a number
of identical parts
3. Unit die to
produce
different parts at
one time
4. Combination
die to produce
several different
parts for an
assembly.
Die Casting vs. Other Processes
Die casting vs. plastic molding - Die casting
produces stronger parts with closer tolerances
that have greater stability and durability. Die cast
parts have greater resistance to temperature
extremes and superior electrical properties.
Die casting vs. sand casting - Die casting
produces parts with thinner walls, closer
dimensional limits and smoother surfaces.
Production is faster and labor costs per casting
are lower. Finishing costs are also less.
Die casting vs. permanent mold - Die
casting offers the same advantages versus
permanent molding as it does compared
with sand casting.
Die casting vs. forging - Die casting
produces more complex shapes with
closer tolerances, thinner walls and lower
finishing costs. Cast coring holes are not
available with forging.
Die casting vs. stamping - Die casting produces
complex shapes with variations possible in
section thickness. One casting may replace
several stampings, resulting in reduced assembly
time.
Die casting vs. screw machine products - Die
casting produces shapes that are difficult or
impossible from bar or tubular stock, while
maintaining tolerances without tooling
adjustments. Die casting requires fewer
operations and reduces waste and scrap.
Advantages:
Excellent dimensional accuracy (dependent on
casting material, but typically 0.1 mm for the first
2.5 cm (0.005 in. for the first inch) and 0.02 mm for
each additional centimeter (0.002 in. for each
additional inch).
Smooth cast surfaces (1-2.5 m).
Thinner walls can be cast as compared to sand and
permanent mold casting (approximately 0.75 mm).
Inserts can be cast-in (such as threaded
inserts, heating elements, and high
strength bearing surfaces).
Reduces or eliminates secondary
machining operations.
Rapid production rates.
Casting tensile strength as high as 415
MPa .
Disadvantages :
Casting weight must be between 30 g and
10 kg.
Casting must be smaller than 600 mm.
High initial cost.
Limited to high-fluidity metals.
A certain amount of porosity is common.
Thickest section should be less than 13 mm.
A large production volume is needed to
make this an economical alternative to
other processes.