Dies, or die casting tooling, are made of alloy tool steels in at least two sections, the fixed die half, or cover half, and the ejector die half, to permit removal of castings. Modern dies also may have moveable slides, cores or other sections to produce holes, threads and other desired shapes in the casting. [...]
There are several variations on the basic process that can be used to produce castings for specific applications. These include: […]
Die casting is one of the fastest and most cost-effective methods for producing a wide range of components. However, to achieve maximum benefits from this process, it is critical that designers collaborate with the die caster at an early stage of the product design and development. […]
Aluminium casting processes are classified as Ingot casting or Mould casting. During the first process, primary or secondary aluminium is cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot which are subsequently transformed in semi- and finished products. […]
There are two basic types of die casting machines: hot-chamber machines and cold-chamber machines. These are rated by how much clamping force they can apply. Typical ratings are between 400 and 4,000 short tons. […]
Advantages: Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and 0.02 mm for each additional centimeter (0.002 in. for each additional inch). […]
There are four major steps in the die casting process. First, the mold is sprayed with lubricant and closed. The lubricant both helps control the temperature of the die and it also assists in the removal of the casting. Molten metal is then shot into the die under high pressure; between 10—175 MPa (1,500—25,000 psi). [...]
Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, and tin based alloys, although ferrous metal die castings are possible. […]
To find the best process you must find the bottlenecks and move them to the beginning of the process. Now finding all the bottlenecks and addressing them appropriately is a challenge, but the answer is so simple: standardize all processes. […]
Surface finish and integrity are two different facets of the cavity quality, but both play an important part in the characteristics of the mold. Much as the machine parameters affect the integrity of the sub-layers of the cavity, they also affect the surface finish. […]