Paybacks As Well As Advances Throughout Die Casting Capability. Diecasting capability has made a lot of other industries advance further and provide mankind with modern conveniences. This technology is one of the many alloy casting methods used in today’s metalworking industry. Die casting parts has been around for more than about ten decades tracing its beginnings from the mid 1800′s.
Practice – The main characteristic of this methodology the injecting or forcing of molten alloy using very high pressures into a mold. The die casting mold, which are also known as dies, are also constructed out of steel. The mold is machined into shape and is used in either a cold chamber die casting machine or a hot chamber diecast machine.
Metals used to create a diecast part is usually made out of a non-ferrous alloy. The metal alloys used favorably in today’s metalworking industry include pewter, tin, lead, 413 aluminum, magnesium zinc, and copper alloys. The process itself uses four basic steps regardless of variations in methodology. The said steps are preparation, filling, ejection, and trim.
The first step involves getting the dies or molds ready. This is accomplished by lubricating the interior cavity of the die. Lubrication makes it easier to remove the casting later in the process. The lubricant used in this procedure also aids in controlling the temperature of the mold.
The next step is injection, which simply requires the use of machinery that exerts thousands of psi. Machines used by today’s manufacturers can exert pressures ranging from 400 tons to 4,000 tons while other variants exert 1,500 to 25,400 psi. The entire injection procedure can last for less than a second if the component to be made is really small, which may weigh less than an ounce. Larger components will require the entire process to take a couple of minutes or even up to three minutes max.
After filling, the diecast item is cooled and is ejected. The final process is called trim, which basically means that scraps if any are taken away from the die cast component. After all four steps in this procedure are done the components will be subject to inspection or additional tooling if warranted by the client.
Clearly, there are other methodologies that other manufacturers implement but this is the most basic one that is utilized today. The other processes are but variants of this basic procedure. A huge factor in procedural variation is due to working with a variety of metal alloys. Each metal alloy has its unique properties that need to be addressed individually.
Examples are, tin and lead alloys characteristically have higher densities. Copper alloys on the other hand are known for extra hardness and high corrosion resistance. These alloys provide the highest types of dimensional stability. Copper is also wear resistant that is fairly comparable to steel items.
Magnesium on the other hand is the most lightweight compared to all the metals used to create diecast items. Although an aluminum alloy is not as light as magnesium alloys it offers a good amount of corrosion resistance. Lastly, zinc alloys can be easily plated and are the easiest metal alloys to cast.