Introduction

Die casting is a manufacturing process for

producing metal parts by forcing molten metal
under high pressure into a die cavity. Generally
speaking, these die or mold cavities are
created with hardened tool steel that have
been previously machined to the net shape or
near net shape of the die cast parts. This
process allows products to be made with high
degree of accuracy and repeatibility. The die
casting process also produce fine details such
as textured surfaces or names without
requiring further processing.

The die casting process usually produce parts

using primarily non-ferrous metals, such as
zinc, copper, aluminum and magnesium. Over
the years, many different alloys have been
developed to meet certain type of needs and
requirements of each application.

Type of die casting processes

The die casting process can be further divided

into two different categories:

Hot Chamber Die Casting

Cold Chamber Die Casting
Hot Chamber Die Casting is the process where
the injection system is immersed in pool of
molten metal hence the name. The furnace is
attached to the machine via a feeding system
called a gooseneck. As the cycle begins the
piston will retracts, which allows the molten
metal to fill the gooseneck from a port in the
injection cylinder. As the plunger move
downwards, it seals the port and forces the
molten metal through the gooseneck and
nozzle into the die. Once the metal solidifies,
the plunger will pull upwards. Afterwards, the
die will open and the part is ejected. The
advantage this process its short cycle time as it
does not require metal to be transported from
a separate furnace. Unfortunately, this die
casting process is only suitable for alloys that

do not attack the injection cylinder such as

zinc, magnesium and copper.
Cold Chamber Die Casting is the process of
using a ladle to transport the molten metal
from the holding furnace into the unheated
shot chamber or injection cylinder. This metal
is then shot into the die by using a hydraulic
piston. The main disadvantage of this process
is that it is relatively slower compared to the
Hot Chamber Die Casting process. However,
this process is primarily used for manufacturing
aluminum parts as molten aluminum alloys
have a tendency to attack and erode the metal
cylinders, plungers and dies greatly shortening
their tool life.
History
The die casting process dates back to the mid
1800s, when a patent was awarded to Sturges
in 1849 for the first manually operated
machine for casting printing type. However, it
was not until 20 years later that this process
has been used to produce other consumer
products such as phonographs and cash
registers.
In the beginnings, tin and lead are the primary

alloys used for the die casting process, but

these alloys have been replaced by zinc and
aluminum since the 1920s.
As technology advances, the die casting
process has become more and more efficient.
New technologies allow greater pressure in the
injection process, thus allowing us to produce
parts that are closer to net shape and higher
integrity than ever before.
Advantages of Die Casting Parts
One of the main advantages of die casting is
the ability to produce parts and products with a
wide range of shape and sizes. Unlike other
manufacturing processes such as extrusion,
the die casting process does not limit the
shape of parts and in most cases will be the
net shape of the parts.
Durability:
Unlike plastic parts, die cast parts are stronger
than their plastic counterparts. In most cases,
this allows parts to be produced with thinner
walls while maintaining the strength that is
required for its application. Furthermore, die
cast parts are able to withstand to a broader

range of temperature, making it more ideal in

harsh temperatures and working environments.
Mass production at high speed:
Since the die casting process can allow
manufacturers to produce complex parts to net
shape, there is little or no machining processes
required thus reducing the production time
making die casting one of the most effective
process to mass produce non-ferrous metal
complex parts.
Green Manufacturing:
How long does it takes for plastic to
biodegrade? According to scientists, plastics
takes at least a few hundreds of years to
degrade fully. This means that obsolete plastic
products are pilled up in the landfills, polluting
our beaches, killing millions of sea animals and
causing health hazards to the inhabitants in
our neighborhoods. Unlike plastic, die casting
parts are primarily made of recycled material.
On average, approximately 95% of the metal is
recycled from salvaged parts making it a
sustainable material that can be used over and
over again without degradation.

Thinner Wall Castings:

Compared with sand and permanent mold
castings, the die casting process is able to
produce parts with thinner walls due to the
high pressure during the injection process.
This allows lightweight construction as well as
eliminate or reduce the need of secondary
operations.
Casting with inserts:
The die casting process allows inserts to be
cast-in to form certain features such as
threaded inserts, heating elements or high
strength bearing surfaces.