The casting process is subdivided into two distinct

subgroups:
1 - Expendable mold casting
(sand, plastic, shell, and investment (lost-wax technique) mouldings.)

2 - Nonexpendable mold casting

(permanent, die, centrifugal, and continuous casting).

Classification of die casting:

(a)Gravity Die Casting (also called permanent mould process)
(b)Pressure Die Casting

Die Casting Process Flow

(Image courtesy: wiki)

[ pressure die Casting Techniques]

[Pressure-die casting]

[Die cast Part of automobile]

[Die casting Fence fittings]

(Image courtesy: wiki)

There are two basic types of die casting machines:

(1)hot-chamber machines
(2) cold-chamber machines

(Hot Die Casting machine)

(Image courtesy:
wiki)

cold-die-casting
machine
(Image courtesy: wiki)

Table : Capabilities of major casting

processes
Attribute/p sand
rocess
Max. size
Several
tons
Dim.
>0.6
tolerance
mm
Surface
>200
finish
rms
Min.
>6 mm
thickness
Economic
Any no.
quantity

investm
ent
Upto 20
kg
>0.1
mm
>60 rms

Gravity
die
Upto 50
kg
>0.4 mm

Pressure
die
Upto 8 kg

>1.5
mm
>100

>4.5 mm

>0.8 mm

>500

>2500

>.05 mm

>150 rms >30 rms

( Cooling Curve for casting)

(Image courtesy: wiki)
Chvorinov's rule:

The local solidification time can be calculated using Chvorinov's rule,

which is:

Structure:

(Intermediate cooling rates from

melt result in a dendritic
microstructure.

(Image courtesy: wiki)

Minimum wall thicknesses and minimum draft angles for die casting
are :

Material

Aluminum alloys

Zinc alloys

Copper alloys (Brass)

Min. Thickness
mm (in)

0.9 mm

0.6 mm

1.25 mm

Min. Draft Angle ()

0.5

0.25

0.7

Die casting materials:

Zinc: the easiest alloy to cast; high ductility; high
impact strength; easily plated; economical for small
parts; promotes long die life.
Aluminum: lightweight; high dimensional stability
for complex shapes and thin walls;.
Magnesium: the easiest alloy to machine;
excellent strength-to-weight ratio; lightest alloy
commonly die cast.
Copper: high hardness; high corrosion resistance; highest
mechanical properties of alloys die cast; excellent wear
resistance.

Common aluminum alloys for die casting are summarized as fol

Silicon

Copper

Tensile Strength
MPa (ksi)

AA 380
(UNS A03800)

8.5 %

3.5 %

324
(47)

Fair easy to fill

AA 384
(UNS A03840)

11 %

4%

331
(48)

Easy to fill

AA 386
(UNS A03860)

9.5 %

0.6 %

317
(46)

Good corrosion
resistance

AA 390
(UNS A03900)

17 %

4.5 %

283
(41)

Good wear
resistance

Material

Properties

Advantages:
Excellent dimensional accuracy
Smooth cast surfaces (12.5 m rms).
Thinner walls can be cast
Inserts can be cast-in (such as threaded inserts, heating elements )
Reduces or eliminates secondary machining operations.
Rapid production rates.
tensile strength as high as 415 MPa .

Disadvantages:
Casting weight must be between 30 grams and 10 kg
Casting must be smaller than 600 mm
High initial cost.
Limited to high-fluidity metals.
A certain amount of porosity is common.
Thickest section should be less than 13 mm
A large production volume is needed to make this an economical .

THANK YOU