Die Casting is a metal casting process that involves forcing molten metal under high pressure into a mold cavity. Diecasting molds are typically made of hardened tool steel and are shaped like injection molds. This process is a popular option for manufacturers looking to create precision-machined components that will last for many years.
Depending on the materials, die casting can be done with various alloys. The most common alloy for castings is magnesium, a silvery white metal with low weight. Another popular alloy is cast iron, which is a malleable metal. It is often toughened with a heat treatment process. Die casting is a highly complex process. Once a part has been designed, it must undergo a series of processes to make it a final product.
The design geometry of a diecast part determines how the part fills and cools and the degree of stress. The design geometry is influenced by the type of metal, the wall’s thickness, and the surface’s depth. A mathematical formula determines the draft angle, and the fillet radii help to redirect stress away from sharp interior corners and prevent cracking during straightening. In addition to design geometry, the part must be designed to meet specifications, which can vary depending on the design.
Die casting is a high-volume process that requires a large amount of metal and a large amount of pressure. The process of die casting begins with the preparation of a custom die. The die is held in place between two plates during the casting process. These dies are usually composed of two halves, one of which is the cover and the other is the ejector. The cover die is stationary, while the ejector die is movable. A clamping system connects the die halves. The ejector die is then opened after a predetermined amount of time.
A steel mold is used to create the mold for the die casting process. The steel mold must be made of two sections. One of the sections is stationary, while the other is moved around to allow the metal to cool into the die cavity. This process can be highly complex and requires two sets of dies. The first die is made of high-grade steel and the second die is made of a copper-based alloy.
The die casting process produces parts that have tight tolerances and are accurate. In addition, these parts are corrosion-resistant. Another key advantage of diecasting is its high production capacity. The process can produce thousands of castings from one mold. It also offers greater durability than plastic moldings, susceptible to ultraviolet rays, heat, and stress cracking.
The main components of die casting are the molds and the dies. The dies can be made of a variety of metals. The most common metal used in die casting is high grade tool steel. These steels can withstand 100 to 150,000 cycles. Aside from steel, tungsten and vanadium are common metals used in die casting.
The dies are designed to withstand the heat and pressure of the molten metal. The molten metal is then injected into the mold at a high temperature, and then rapidly cooled. After this, the solidified part is easily ejected from the mold. This process produces precise and accurate parts in mass quantities.
The dies are sprayed with lubricant to allow clean part release. This lubricant is mixed with water and sprayed onto the heated steel die. The dies are then clamped together under high pressure. The required pressure depends on the part size, number of cavities, and side cores. The process has many steps. The process takes about an hour. A part needs to undergo four stages. First, the die needs to be closed. Then, the die is cooled. The next step is finishing, where the part is finished to the customer’s specifications. If the part is perfect, the process is considered a success.
The dies have the ability to shape the molten metal. The material used in die casting has better strength than its plastic counterpart. Because they consist of a single piece, a diecast will be stronger than a plastic component.