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Die Casting

Die casting is a precision casting technique that uses a permanent metal mould, or die, into which molten metal is poured directly. Metal is typically forced into the mould under pressure but gravity-feed systems are also used. Tooling costs and other capital costs are high due to the cost of designing dies. Operational costs, however, are relatively low, due to the high level of automation and the small number of production steps (i.e. direct pouring into a permanent mould rather than preparing destroyable patterns and/or moulds). The process, therefore, is best suited to mass production. Die casting is most suitable for non-ferrous metals with relatively low melting points (i.e. around 870oC) such as lead, zinc, aluminum, magnesium and some copper alloys (Luther, 1999).

Die MakingCasting Assembly
Metal Injection and PressingRelease

Casing metals with high melting points, including iron, steel and other ferrous metals, reduces die life. Dies are usually made from two blocks of steel, each containing part of the cavity, which are locked together while the casting is being made. Retractable and removable cores are used to form internal surfaces. Molten metal is injected into the die and held under pressure until it cools and solidifies. The die halves are then opened and the casting is removed, usually by means of an automatic ejection system. The die is cleaned between each casting cycle, preheated and lubricated to reduce wear on the die, to improve surface quality and to aid ejection. Mould coating material can also be used to protect the molten metal from the relatively cool and conductive surface of the mould. Cooling systems are often used to maintain the desired operating temperature.

Die Casting Furnace

Advantages of Die Casting

Once capital is in place, operating costs are low relative to most other casting processes. This is due to the reduced number of
process steps, the elimination of temporary moulds and patterns from the process, and the lower volume of materials that need to
be handled.

Dies can sustain very high production rates (i.e. over 400 shots per hour). Total cost of castings can be relatively low at high levels
of production.

High design flexibility and complexity allows products to be manufactured from a single casting instead of from an assembly of
cast components. Good accuracy, consistency and surface finish are possible, with high metal yields.

Cleaning, machining, finishing and fabrication costs are low.

There are low levels of waste due to elimination of refractory material ,leading to a cleaner work environment.




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