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About Die Castings
Die casting is a metal forming process in which molten
metal is put under pressure and injected into a die. The molten metal
enters the die cavity through sprue holes in the fixed die half. The
melt is directed to the cavity by runners (passageways) and gates (inlets)
in the ejector half. Locking pins on the die secure the two halves together.
The metal, kept just above its melting temperature, quickly solidifies
into the shape of the die casting. Ejector pins remove the die cast part.
Die castings are made from alloy tool steels. They have at least two
sections to permit the removal of castings, the fixed die, or cover,
half and the ejector die half. Some dies also have parts, such as removable
slides and cores, to produce holes, threads and other desired shapes
in the casting. Openings in the die allow the addition of coolant and
lubricant. Dies are either air- or water-cooled. The cooling of the die
provides for quick cycling and is one of the factors in the high rate
of production. It also gives a fine grain structure and superior strength
and finish to the metal castings. The molds used by die casting manufacturers
will perform up to 5 million shots in its lifetime.
The services provided by die casting manufacturers have many advantages
over other processes. Die casting is efficient and economical, offering
a wide range of durable shapes and components. Little or no machining
is required after die castings are made because the process provides
very close tolerances for even complex part shapes. Metal castings can
be easily plated or finished. Die castings are dimensionally stable and
heat resistant. These lightweight parts, even while having thin walls,
retain the strength of an alloy because they do not consist of separate
parts welded together.
Die casting manufacturers utilize a number of materials, including zinc,
aluminum, magnesium, copper, lead and tin. Zinc is the easiest alloy
to cast, has a low melting point and is economical and easily palatable.
Zinc also has high impact strength, offers high ductability and promotes
long die life. Aluminum alloys possess high dimensional stability for
complex shapes and thin walls. Aluminum die casts are of a lightweight
alloy that has good corrosion resistance, mechanical properties, high
thermal and electrical conductivity and strength at high temperatures.
Along with being the easiest alloy to machine, magnesium is also the
lightest typically die cast. Magnesium die casting also has excellent
strength-to-weight ratio. Copper is one of the hardest alloys and offers
the highest mechanical properties of any other alloy that is cast. A
dimensionally stable alloy, copper has high corrosion and wear resistance
and strength approaching that of steel parts. Lead and tin are used for
special forms of corrosion resistance. Although they have high density,
parts with extremely close dimensions are able to be formed from lead
castings and tin castings.
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Types of Die Castings
- are die castings made from aluminum materials.
- are commonly used in the production
of hardware and tools because of the great resistance of aluminum castings
to corrosion and high temperatures, as well as their conductivity.
In addition, aluminum castings are used in applications requiring the
production of intricate part features and components.
- , which include engine blocks, cylinder heads,
brake calipers and discs and suspension components, are increasingly
being
manufactured out of lightweight material, such as aluminum, to economize
fuel consumption by decreasing the overall weight of the vehicle.
- are used in the architectural and construction industries
and in decorative applications, such as doorknobs.
- are used in applications requiring high strength,
making them ideal for use in the architectural and construction
industries.
- are used in applications requiring exceptional
strength and resistance to corrosion. Copper castings consist
of brass and bronze castings.
- shape metal by putting pressure on molten metal in a die.
- are produced by pouring molten aluminum into
a metallic tool at a casting temperature of 750¼. Gravity
die castings have good tolerances and surface finishing.
- have very thin walls. The metal enters
the die cavity at high speeds and under great pressure,
which increases the chance of porosity.
- offer great corrosion resistance and are used in
the production of parts in the plumbing industry. Lead
castings, particularly tin castings, also provide close production
tolerances but are generally
not as strong as other diecast metals.
- are formed when metal from an airtight
furnace is transferred into a metallic tool through
a rising tube. Low pressure
die casting is suitable for relatively small lot sizes
and for applications in which heat treatment is needed to improve
the
mechanical
properties.
- are particularly useful in applications where
weight is a factor. Magnesium die castings are very
lightweight and cost-effective, especially in comparison to other
diecast
metals.
- are metal impressions made with molds.
- are often used in the production of small parts
for the electronics and automotive industries.
Zinc castings lend themselves
well to secondary operations such as painting and
plating.
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