PRESSURE DIE-CASTING

Presented by -
o Utsav Gupta
o Aryan Chauhan
Introduction
In this process the molten metal is forced into a permanent metal
mould or die, under certain pressure. This process is a highly
efficient metal casting process that offers numerous advantages over
other methods. This presentation will cover the process and
advantages of pressure die casting.
What is Pressure Die Casting ?
Pressure die casting is a metal casting process in which molten metal is injected
into a steel die under high pressure. The metal solidifies in the die, and the part
is then ejected, this process is used to produce complex, high precision parts
with excellent surface finishes.
Die casting equipment was invented in 1838 for the purpose of producing
movable type for the printing industry. The first die casting-related patent was
granted in 1849 for a small hand-operated machine for the purpose of
mechanized printing type production.
Advantages of Pressure Die Casting
1.High Production Rates: Die casting is a high-speed process, making it suitable for mass
production. It can produce a large number of parts quickly, improving manufacturing efficiency.
2.Excellent Surface Finish: Parts produced through pressure die casting typically have a smooth
and fine surface finish, reducing the need for additional finishing operations like machining or
polishing.
3.Complex Shapes: Pressure die casting can create intricate and complex shapes with ease. This is
particularly valuable when manufacturing parts with challenging geometries or detailed features.
4.High Precision and Accuracy: Pressure die casting produces parts with excellent dimensional
accuracy and consistency. The process allows for tight tolerances, ensuring that each part meets
the required specifications.
5.Minimal Material Waste: The process is highly efficient in terms of material usage. Minimal
material is wasted, reducing material costs and environmental impact.
6.Strength and Durability: Parts produced by die casting tend to have excellent mechanical
properties, including high strength and durability. This makes them suitable for applications
requiring robust components.
Types of Pressure Die Casting
There are various types of Pressure die casting machines but in this presentation we are
going to present about two main types of pressure die casting machine i.e.
1. Hot Chamber Die-Casting Machine – A hot chamber die casting machine is a
specialized industrial equipment used for the hot chamber die casting process. In short,
it is a machine designed to melt and inject low melting point metals (e.g., zinc or
magnesium) into a mold to produce complex metal parts.
2. Cold Chamber Die-Casting Machine - A cold chamber die casting
machine is an industrial equipment used for the cold chamber die
casting process. In short, it is a machine designed to produce complex
metal parts by injecting high melting point metals (e.g., aluminum or
copper) into a mold.
The Pressure die-casting Process
The pressure die casting process involves several steps including die preparation, molten metal injection,
solidification and part ejection, the process is highly automated, with computer-controlled machines
ensuring consistent quality and accuracy.
Die Preparation – the first step in the process is die preparation, the die casting die are mainly of 3 types
–
◦ Single Impression Dies, i.e. those which have only a single die cavity and can produce only one
casting at a time.
◦ Multi Impression Dies, i.e. those which have more than one cavity and all of them are alike, they will
produce as many castings at a time as the number of cavities in them.
◦ Combination Dies, i.e. those which contain more than one cavity as the multi impression dies, but the
cavities in it are not alike.
The die is coated with a lubricant to prevent sticking, and the mold cavity is cooled to increase the rate
of solidification. the die is then closed and clamped shut.
Molten Metal Injection
The desired metal, often aluminum, zinc, magnesium, or another low to medium melting point
alloy, is melted in a separate furnace or crucible. The metal is heated to its liquid state at
temperatures suitable for the specific alloy being used.
The pressure die casting machine includes an injection system. In the "hot chamber" die casting
process, the furnace containing the molten metal is integrated into the machine. In contrast, in the
"cold chamber" die casting process, the molten metal is kept externally and is ladled into the
machine.
The molten metal is then injected into the die cavity under high pressure.
Solidification and Part Ejection
◦ Solidification is the phase of the die casting process during which the injected
molten metal cools and transforms from a liquid state to a solid state, taking on the
shape of the mold. After the molten metal fills the mold cavity, the mold is cooled
to accelerate the solidification process. Cooling can occur through various means,
including the use of cooling channels, water or oil circulation, or air cooling,
depending on the die casting machine and process.
◦ Part ejection is the step in die casting where the solidified metal part is removed
from the mold cavity. After the metal has solidified, the mold halves are separated.
This can be achieved using hydraulic mechanisms or other methods, depending on
the die casting machine's design.
Materials used in Die-Casting
◦ Aluminum alloys
◦ Zinc alloys
◦ Magnesium alloys
◦ Copper alloys
Factors Influencing Material Selection in Pressure Die Casting are mainly its part
design, mechanical property, thermal conductivity, weight, cost, corrosion
resistance etc.
Application of Pressure Die Casting
1.Automotive Industry: Engine components, such as cylinder heads and
engine blocks.
2.Consumer Electronics: Housing and frames for smartphones, laptops,
and tablets.
3.Aerospace Industry: Aircraft components, including brackets, fittings,
and interior parts.
4.Medical Devices: Surgical instruments and equipment components.
5.Lighting Industry: Lighting fixtures, including lamp housings and
reflectors.
6.Firearms Industry: Firearm components, such as trigger guards,
receivers, and pistol frames.
 Conclusion
Pressure die casting is highly efficient metal casting process that
offers numerous advantages over other methods. Its ability to
produce complex parts with excellent finishes makes it a popular
choice for a wide range of industries.