Working of Die Casting in an Aluminum Foundry

Many of your daily use items are made with the process known as die casting. It is a process wherein a required shape, metal is molded. In our use of the products, It's a rather simple (but intense) procedure that is often taken for granted made through die casting.

By forcing liquid metal into a mold this process is completed under extremely high pressures. The molds come in two pieces and are made of steel usually. They work comparable to injection molds and are shaped. Metals like zinc and aluminum make up most of these diecasts. The aluminum casting part is made from aluminum.

Because the process is so intense and costly, it is usually limited to high volumes of production. The entire process consists of only four main steps. This keeps makes die casting best suited and incremental costs down towards large amounts of medium to small-sized castings. By its polished and good quality surface finish, you can know something has been die-cast. The castings also have very consistent measurements.

In the early 1800s, Die casting was first invented. It helped in the growth of consumer products soon after although it was first used for the printing industry. Affordable in high volumes, it made the production of intricate parts. Two different types of die-cast machines are there basically - cold and hot chamber. On the type of metal used, the selection of chamber used in the process of die casting is cold or hot largely depends.

To feed the die, hot chamber machines use a pool of liquid or molten metal. After this, a piston forces the metal into the die itself and out. By convenience and fast cycle times, it is characterized. Unfortunately, metals having very high melting points cannot be used. With metals like lead, tin, and zinc-based metals, these chambers are used.

When hot chamber machines are not possible to use, Cold chamber machines are used. Cold chamber machines are used in the aluminum die casting part. Copper and magnesium are other metals used with this type of machine. However, the metal needs to be melted in a separate furnace with cold chamber die casting machines.

The four steps of die casting are: die preparation, ejection, filling, and shakeout. First to ease the removal of the casting and help control the temperature the die is sprayed with a lubricant. Into them under intense pressure, Dies are then closed while the molten metal is injected. As the casting hardens, Pressure is maintained in the die. Using the pins, the mold is then opened and the casting is ejected. Separated from the actual casting, the shakeout is where scrap. To make sure everything is ok, after this the casting is inspected and at a very fast rate, the whole process repeats. This is how some of your more commonly used items are produced.

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Created on Aug 20th 2020 11:09. Viewed 234 times.

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