Die cast metal
Metal die casting (or die cast metal) is an effective method to create a wide range of shapes and is one of the most mass produced ingredients available today. Its application is so ubiquitous that it comes around in our lives. Many toy cars are manufactured by die casting, as are real cars. Die cast metal offers high precision in its products with good quality surface, suitable for a wide range of products without the need for additional polishing or machining.
Process
Die cast metal method requires the creation of a steel mold (called a die,) of a part for casting, which, once created, is fitted into the molding machine and pumped under pressure with the molten metal or desired alloy. There are two methods of injection, which are hot and cold chambers.
Hot Chamber die casting
Cold Chamber die casting
Hot-chamber die casting machines use an oil or gas-powered plunger to insert the machine-heated molten metal into the mold. The pull-back plunger allows the molten metal to fill what is known as a gooseneck, once the liquid metal has filled the gooseneck, the plunger can squeeze the liquid metal into the mold. The clamping force used to pump the metal can range from 400-4000 tons. This method has fast cycle times that can be as low as a few seconds when producing small parts.
A cold-chamber die casting machine that does not heat metal, molten metal must be fed into the cold chamber manually or by an automatic ladle system, the molten metal is then pressed into the mold by the hydraulic piston at high pressure.
Advantages and Disadvantages of Die cast metal
Advantages
Disadvantages
Height accuracy is achievable
Fast production
Thinner walls can be achieved when compared to investment casting (0.6mm -0.8mm)
A variety of shapes are possible
Simple assembly (outer threads can be cast or holes cut according to inner drill bit size)
Good finishing (1 m – 2.5 m) (depending on the purpose, not all parts will require additional finishing)
Casting should be less than 600mm and the thickest part of wall should be kept below 13mm
High initial cost (Mold and machine setup cost)
A large production volume is required to make the process cost effective
Some porosity is common with pressure casting
Pressure casting is limited to highly portable metals (Zinc, Aluminum, Magnesium, Copper, Lead and Tin)
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