DIE CASTING

Objective:
To prepare the products by DIE CASTING (either by hot or by cold chamber)

THEORY:
Die casting is the permanent metal casting process that is characterized by forcing
molten metal under high pressure into a mold cavity. By this process, large
numbers of castings are produced from it. The mold cavity which is the replica of
the product which is to be casted is created in the mold of metal (specific) by using two
hardened tool steel dies which have been machined into shape and work similarly to an
injection mold during the process.

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These die steels have very high melting point and must resist very high temperatures.
When the process is used for steel and cast iron. The mold life tends to be extremely
short. Even for the low melting temperature metals the mold life is limited because the
erosion by the molten and thermal fatigue. For this, grey cast iron is best because it
has very low erosion and thermal fatigue. The metal die is prepared by different
machining operations. The die is in two halves. One half is fixed while other is moveable
to allow the casting to be removed. The die is of metal so allows quick cooling of
castings, resulting in smaller and compacted grain structure. No doubt there are also
many allowances like shrinkage work on these defects same as in sand casting
process.
Generally, there are two types of DIE CASTING, which are as follows:

1. Gravity die casting.

2. Pressure die casting

GRAVITY DIE CASTING:

It is the general die casting process in which molten metal is poured into
mould metal which is in the die mould without any pressure. Both ferrous
and non-ferrous metals can be casted. It has fine grained structure. But its
production rate is slow. This casting is not so smooth or dimensionally
accurate. In this casting process, just take the molten metal from furnace by
ladle and pour into the mould. After pouring, open the mould and we get our
casting product but we have to perform some steps which are as follows:

Pre-heat the mould.

The mould cavity should be lubricated.
Pour molten metal in a proper way neither quickly nor slowly.
Wait for cooling, open the mould and eject the casting product.
Work on finishing steps like smoothing of surface and edges, or internal
space (if cores are used in the process for internal cavity).

ADVANTAGES AND DISADVANTAGES:

As the component size and complexity increases the process becomes
more expensive and becomes uneconomical.

 It will also cause difficulty in handling the die and in extracting the casting
from the die with reduction in dimensional accuracy and soundness of the
casting.
The GDC process is capable of achieving 20% higher mechanical
properties than that of a sand casting because of faster rate of
solidification imparting better grain size.
The process can be automated and also can produce semi-gravity diecastings.

PRESSURE DIE CASTING:

The casting of a metal, when molten metal is poured in mould

cavity created in the mould by an amount of pressure is known as
Pressure Die Casting.
The pressure die casting has the same principle as the gravity die casting
but only one thing is different here which is the pouring of molten metal.
The pressure is transferred to the molten metal by men or by machine
(hydraulic) operations through the plunger. This casting are specified
depending upon their capacity (clamping forces). This capacity
determines the strength of the casting. More the pressure is more the
molten metal will be compacted.
Most die castings are made from non-ferrous metals, specifically zinc,
copper, Aluminium, magnesium, lead, pewter and tin-based alloys.
Depending on the type of metal being cast, a hot- or cold-chamber
machine is used.

For this pressure die casting is further classified in two process, which are
as follows:
Cold chamber pressure die casting.
Hot chamber pressure die casting.
In both the processes, Lubricants must be sprayed into the cavity to
prevent sticking. Venting holes and passageways must be built into the
dies at the parting line to evacuate the air and gasses in the cavity. Flash
is to be used in both processes because the liquid metal under high
pressure squeezes into the small space between the die halves. At the
parting line or into the clearance around the cores and ejector pins. It is
trimmed from the part after solidification along with sprue and gating
system.

COLD CHAMBER PRESSURE DIE CASTING:

In this pressure die casting process, the basin of molten metal is

not a part of the m/c. molten metal is poured into an unheated
chamber from an external melting container.
Machine:
The cold-chamber m/c consists of following parts:
Plunger: It is a vertical or horizontal spring-piston to push the molten
metal into the die cavity.
Shot sleeve: It is a cylinder where molten metal is poured in.
Die: The two halves die is connected in front of the shot sleeve.
Ejector pins: These are used to open the die and eject the casting out.
Hydraulic circuit: This operates the pressure cylinders and automates all
the process.
.
Process:
A die-cycle is completed in following steps:
The ladle brings the molten metal from the furnace and pours it into the
shot sleeve.
Plunger pushes the molten metal into the cavity in the die, with a pressure
of nearly 9800 psi.
After the die is filled, metal is left to solidify.
Pressure is maintained during solidification by a plunger or compressed
air.
After solidification, pressure is removed, the die is opened.
The hydraulic operated knock-out/ejector pins are used to eject the
casting out.

 The die is closed and m/c becomes ready for another casting.
The runner part is removed from the casting and as casting is very smooth
so no special machining process is required.

Materials to be used:
Such Alloys Used Include Aluminium, brass and magnesium.

Hot Chamber Die Casting:

In this pressure die casting process, the basin of molten metal is connected
with the hot chamber die casting machine, in which plunger is powered by
hydraulic machine.
Machine:
The hot-chamber die casting m/c consists of:
Plunger: It is a vertical piston for pushing molten metal. Compressed air is also used
for this procedure.
Gooseneck nozzle: For squirting out metal with high velocity and pressure.
Molten metal basin: For melting metal to provide a continuous supply of metal.
Die: It contains a cavity of required shape.
Ejector pins: For opening the die and removing the casting
Hydraulic circuit: This operates the pressure cylinders and automates all the process.
Process:
A die-cycle is completed in following steps:
The gooseneck is submerged in molten metal basin.
The plunger in upper position lets the molten metal flow inside.
When metal is filled in the neck; in case of air-operated m/c, it is raised up to the die
and locked in contact with the die opening.
In case of the plunger m/c, the holes are closed to trap the molten metal inside the
neck, on the down stroke.
Plunger is pushed down by a pressure of nearly 5000 psi to inject the molten metal
into the cavity in the die.
After the die is filled, metal is left to solidify.

 Pressure is maintained during solidification by a plunger or compressed air.

After solidification, pressure is removed, the die is opened and knock-out/ejector pins
are used to eject the casting out.
The die is closed and m/c becomes ready for another casting.
The runner part is removed from the casting and as casting is very smooth so no
special machining process is required.
The production rate of this process is high due to direct use of the molten metal from
the furnace.

MATERIALS TO Be USED:
Zinc, tin and lead
Advantages of pressure die casting:
High production rates can be possible
Good surface finish, smooth cavity produces smooth castings.
Large number of castings can be produced by metal mold and economic
justification for large production.
Rapid cooling provides small grains size and good strength.
The process is very fast and can produce large number of castings in a
small time.
As casting is done under high pressure so the grains are highly
compacted, increasing the strength of the casting.
High dimensional accuracy.
High melting alloys cannot be prepared in hot chamber m/c as such hot
metals e.g.
Disadvantages of pressure die casting:

 Expert metallurgical and production control is required for perfect

castings.
Careful gating and vent systems are to be considered.
Machining for producing the cavity is expensive.
The metals such as iron and steel cannot be die-cast.

PROCEDURE:
Pre-heat the mould and lubricating the mould cavity produced inside the
mould.
Pour molten metal into the mould by ladle.
If pressure die casting is used then metal is poured into mould by an amount of
pressure through plunger.
Then wait for the cooling of metal.
Open the mould and eject the casting metal.
Now smoothing the surface or working on edges or other finishing processes.

PRECAUTIONS:

Metal should be melt to an appropriate temperature.

Must pre-heat the mould.
Pour metal into mould cavity properly neither fast nor slowly.
Carefully work on finishing processes.