Presented by:

Chandra bhan prajapati

2008AMD2934

The casting process is subdivided into two distinct subgroups:
1 - Expendable mold casting
(sand, plastic, shell, and investment (lost-wax technique) mouldings.)
2 - Nonexpendable mold casting
(permanent, die, centrifugal, and continuous casting).
Classification of die casting:
(a)Gravity Die Casting (also called permanent mould process)

(b)Pressure Die Casting
Die Casting Process Flow
(Image courtesy: wiki)
[Pressure-die casting]
[ pressure die Casting Techniques]
[Die cast Part of automobile]
[Die casting Fence fittings]
(Image courtesy: wiki)
(Hot Die Casting machine)


(Image courtesy: wiki)
There are two basic types of die casting machines:
(1)hot-chamber machines
(2) cold-chamber machines
cold-die-casting machine
(Image courtesy: wiki)
Attribute/proc
ess
sand investment Gravity die Pressure die
Max. size Several
tons
Upto 20 kg Upto 50 kg Upto 8 kg
Dim. tolerance >0.6 mm >0.1 mm >0.4 mm >.05 mm
Surface finish >200 rms >60 rms >150 rms >30 rms
Min. thickness >6 mm >1.5 mm >4.5 mm >0.8 mm
Economic
quantity
Any no. >100 >500 >2500
Table : Capabilities of major casting processes
( Cooling Curve for casting)
(Image courtesy: wiki)
Chvorinov's rule:

The local solidification time can be calculated using Chvorinov's rule,
which is:

Structure:
(Intermediate cooling rates from melt
result in a dendritic microstructure.
(Image courtesy: wiki)
Material
Min. Thickness
mm (in)
Min. Draft Angle ()
Aluminum alloys
0.9 mm

0.5
Zinc alloys
0.6 mm

0.25
Copper alloys (Brass)
1.25 mm

0.7
Minimum wall thicknesses and minimum draft angles for die casting
are :
Die casting materials:

Zinc: the easiest alloy to cast; high ductility; high impact
strength; easily plated; economical for small parts; promotes
long die life.

Aluminum: lightweight; high dimensional stability for complex
shapes and thin walls;.

Magnesium: the easiest alloy to machine; excellent strength-
to-weight ratio; lightest alloy commonly die cast.

Copper: high hardness; high corrosion resistance; highest
mechanical properties of alloys die cast; excellent wear
resistance.
Material Silicon Copper
Tensile Strength
MPa (ksi)
Properties
AA 380
(UNS A03800)
8.5 % 3.5 %
324
(47)
Fair easy to fill
AA 384
(UNS A03840)
11 % 4 %
331
(48)
Easy to fill
AA 386
(UNS A03860)
9.5 % 0.6 %
317
(46)
Good corrosion
resistance
AA 390
(UNS A03900)
17 % 4.5 %
283
(41)
Good wear
resistance
Common aluminum alloys for die casting are summarized as follows:
Advantages:
Excellent dimensional accuracy
Smooth cast surfaces (12.5 m rms).
Thinner walls can be cast
Inserts can be cast-in (such as threaded inserts, heating elements )
Reduces or eliminates secondary machining operations.
Rapid production rates.
tensile strength as high as 415 MPa .
Disadvantages:
Casting weight must be between 30 grams 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 .
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