Versatile Applications and Developments In Pressure Die Casting
Manufacturing processes include impressions of metallic parts like small screws or bolts. Making them with perfection isn’t an art of the human hand. But the advanced metallurgical techniques and equipment have made it possible. Swift and mass production with less cost and effort is the new trend being followed in the industries. Among the widely used processes, press die casting is no new in the metallic field. Over the years, the process itself changed and developed with varying parameters. What and why die casting is used for is not quite popular in the outer world. Let us dive deep into the insight of origin and its applications.
What Is It?
The process utilizes high pressure to pour hot molten metal into molds called casts to shape them as desired. It is low cost and accurate in work due to machine procedures. Due to the advantages observed, the process is widely adopted.
• Components with complex designs and parts are easy to make without imperfections.
• Dimensions are uniform and accurate among all the manufactured components.
•Smooth outer surface without irregularities. The metallic composition throughout the component is uniform without air gaps or internal cracks.
• Using pre-designed casts reduces the scrap material and, in turn, reduces waste and pollution.
How Does The Process Work?
Depending on the alloy used, the process is segregated to low pressure or high-pressure variations.
Aluminum, zinc, and magnesium are the most common metals used in individual or alloy forms. The equipment setup is fairly the same for both containing casts inside moving pistons. The metal is poured using the spoon and injection pistons.
The variations in temperature of shot chambers and the pressure applied to vary the designs used for different alloys.
1. Hot chambers are heated with 35MPa, which is low pressure suitable for low melting points of zinc and magnesium. On the other hand, cold chambers are made for high melting point magnesium and aluminum with pressure around 150MPa.
2. Hot chambers, due to low pressure, hold the metal inside the chamber, then drawn and pushed to mold. In contrast, the cold chamber has external heating and metal melting, which is later injected into casts.
Metals commercially available with sustainable melting points, good plasticity, and strength on cooling down are used for die casting. The equipment itself must resist the pressure and temperature effects. It shouldn’t rust or react with the components it is working with. Usually, die steel like H13 or 8407 is popularly used.
Applications In Industries
Simplicity to use and plenty of advantages, a maximum capacity of components are simultaneously manufactured. With the benefits, the process is widely used in several industries to make parts and components not accurately possible by human hand.
The automobile and aerospace industries need to produce safe and secure engine components. Small non-reachable dimensions are possible through casting. General hardware appliances like pumps or kitchen tools need complex and minute parts. Casting provides uniform and accurate designs for them.
Equipment where ever needs minute parts to be fit needs precision in dimension and excellence in making. New developments and mechanical changes are advancing every day.