Injecting molten metal under high
pressure into steel molds called “dies” produce these
castings. This process can provide a wide range of products because close
tolerances can be consistently held and the efficiency with which metal parts
can be produced. As a result, with the importance of engineering and cost
reduction, die-casting can be beneficial to many industries. The size of
die-castings can be as small as a matchstick to 300 cubic inches. Tolerances in die-casting can be held on the order of .003 to .005. Below
are just a few of the industries die-casting can lend its capabilities
to. Agriculture, Mining, Construction Equipment, Commercial Machinery and
Tools, Communications, Office Equipment, Military, Aerospace, Railroad,
Lighting and Medical industries among others.
PROCESS A steel die is mounted on a die cast
machine. The mating die halves are locked together tight to withstand the
high pressure injected molten metal. The molten metal is then injected
into the die, the metal solidifies and the part is ejected from the
machine. Gates and flash are broken off and other secondary operations
may be needed. The process is repeated in rapid succession thus producing
high quantities of parts in a short period of time. See diagram
below: ADVANTAGES Die-casting is based on all the benefits that if offers over all other
process. They are as follows: - Die cast parts in most cases can produce both simple and
intricate parts thus eliminating the need for secondary operations such as
machining and assembly.
- The steel die is usually expensive and has a
long wear life which in high volume productions runs, result in the mold cost
per castings which is lower than other casting processes.
- Minimal draft
is required.
- Casting surfaces are smoother than other casting
processes.
- Holes and slots can be obtained as cast without
machining and hold very close tolerances.
- Studs, nuts, bushings maybe
cast as integral parts of the casting process. These inserts can be made
of aluminum, brass, steel, stainless steel, bronze and iron.
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