die casting die casting metal casting process characterized forcing metal high pressure mold cavity mold cavity created hardened tool steel dies shape work similarly injection mold process die non metals specifically copper aluminium lead tin based depending type metal cast cold chamber machine casting equipment metal dies represent large capital costs tends limit process high volume production manufacture parts die casting relatively simple involving main steps keeps cost item low especially suited large quantity medium sized die casting produces casting process die characterized good surface finish casting standards dimensional consistency variants free die casting eliminate gas defects direct injection die casting reduce scrap increase yield history die casting equipment invented purpose producing type printing industry die casting related patent granted small hand operated machine purpose printing type production invented machine automated type casting device prominent type equipment publishing industry die casting machine manufactured brooklyn machine sold open market north_america applications grew rapidly die casting growth consumer goods making affordable production intricate parts high volumes released process cast metals main die casting aluminium copper lead tin uncommon die casting possible specific die casting include aluminium aluminium standards following summary advantages easiest metal cast high high impact strength easily economical small parts promotes long die life aluminium lightweight high dimensional stability complex shapes thin walls good resistance good mechanical properties high thermal electrical retains strength high temperatures easiest metal machine excellent strength weight ratio commonly die cast copper high high resistance highest mechanical properties die cast excellent wear resistance excellent dimensional stability strength approaching steel parts high strength copper alternative investment steel parts lead tin high density extremely close dimensional accuracy special forms resistance applications public health reasons type metal lead tin traces copper casting hand set type printing hot foil blocking traditionally cast hand predominantly die cast type casting machines came market added dozens casting machines newspaper office maximum weight limits aluminium brass approximately pounds respectively material defines minimum section thickness minimum draft required casting outlined table section greater equipment basic types die casting machines hot chamber machines cold chamber machines rated force apply typical ratings hot chamber die casting hot chamber die casting known machines rely pool metal feed die beginning cycle machine retracted allows metal fill hydraulic powered forces metal die advantages system include fast cycle times approximately cycles minute convenience melting metal casting machine system limited use low melting point metals aluminium picks iron pool hot chamber machines primarily lead based cold chamber die casting casting hot chamber machines include aluminium large composition aluminium copper process machines start melting metal separate precise metal transported cold chamber machine fed shot chamber injection cylinder shot driven die hydraulic mechanical biggest disadvantage system slower cycle time need transfer metal cold chamber machine mold dies die casting called cover die half die half meet called parting line cover die contains hot chamber machines shot hole cold chamber machines allows metal flow dies feature matches hot chamber machines shot chamber cold chamber machines die contains usually runner path shot hole mold cavity cover die secured stationary casting machine die attached mold cavity cut cavity separate pieces replaced relatively easily bolt die halves dies designed finished casting slide cover half die stay half dies opened assures casting ejected cycle half contains push casting die half driven pin plate accurately drives time force casting damaged pin plate casting prepare shot overall force pin low casting hot damaged excessive force leave mark located places marks casting purpose die components include components usually produce holes opening create details types fixed loose fixed ones oriented parallel pull direction dies direction dies open fixed permanently attached die ones oriented way parallel pull direction removed die cavity shot dies open separate mechanism similar form surfaces use greatly increases cost dies loose called pick outs cast intricate features holes loose inserted die hand cycle ejected end cycle core removed hand loose expensive type core extra labor increased cycle time features dies include water cooling passages parting lines usually wide thin approximately metal starts filling metal quickly scrap high pressure ensures continuous feed metal gate important material properties dies thermal shock resistance elevated temperature important properties include heat checking resistance availability especially larger dies cost longevity die directly dependent temperature metal cycle time dies die casting usually hardened tool cast iron withstand high pressures involved dies expensive resulting high start costs metals cast higher temperatures require dies higher main failure mode die casting dies wear erosion failure modes heat checking thermal fatigue heat checking surface cracks occur die large temperature change cycle thermal fatigue surface cracks occur die large number cycles process following steps traditional die casting known high pressure die casting basis die casting variations die preparation filling dies prepared mold cavity helps control temperature die assists removal casting dies closed metal injected dies high pressure psi mold cavity filled pressure maintained casting dies opened shot shots different multiple die yielding multiple shot ejected finally involves separating scrap includes gate runners flash shot special trim die power press hydraulic press methods shaking include grinding labor intensive method shots gates thin easily broken separation gates finished parts follow scrap recycled yield approximately high pressure injection leads quick fill die required entire cavity fills casting way avoided shape requires difficult fill thin sections creates problem air mold filled quickly little time air escape problem including parting lines highly refined process center casting die perform secondary operations produce features readily tapping hole plating painting inspection casting inspected defects common defects cold defects caused cold dies low metal temperature dirty metal lack possible defects gas hot tears flow marks flow marks marks left surface casting poor sharp corners excessive water based called commonly type health environmental safety reasons unlike based water properly treated remove minerals leave product dies water properly treated minerals cause surface defects types water based oil water water oil semi synthetic synthetic oil water best applied water die surface oil helps release shot common mixture type thirty parts water oil extreme cases ratio include heavy oil animal vegetable synthetic gelatinous room temperature high temperatures found die casting form thin film substances added control thermal properties include aluminium chemical added water based oil based mixed water include soap alcohol historically based diesel fuel commonly good releasing dies small explosion occurred shot led build carbon mold cavity walls easier apply evenly water based advantages advantages die casting excellent dimensional accuracy dependent casting material typically inch inch additional centimeter inch additional inch smooth cast surfaces thou thinner walls cast compared sand permanent mold casting approximately cast heating elements high strength bearing surfaces reduces secondary operations rapid production rates casting strength high casting low metals main disadvantage die casting high capital cost casting equipment required dies related components costly compared casting processes die casting economic process large production volume needed process limited high metals casting weights grams standard die casting process final casting small prevents heat treating heat causes gas pores expand causes micro cracks inside surface related disadvantage die casting parts acceptable parts needing case cast dies variants die casting process developed late 1950s 1960s acronym accurate reliable dense developed combine stable fill directional fast cycle times traditional die casting process process pioneered breakthrough technologies die casting thermal analysis flow fill modeling heat high integrity die indirect squeeze casting explained thermal analysis casting process creating electrical analog thermal system cross section dies drawn paper thermal loads cooling patterns drawn paper water lines represented sizes thermal represented paper system employed fill system required stable flow logical thought processes trial error analysis exist modeling precursor flow fill modeling system die casting process successfully cast low iron aluminum traditional die casting process die similarly heat treated meet military specification finally system employed patented double shot design idea use second located primary apply pressure shot partially solidified perimeter casting cavity shot sleeve system effective lead manufacturer machines discover effective apply sufficient pressure right time later cycle primary indirect squeeze casting free allowed cast free casting process identical standard process oxygen injected die shot purge air mold cavity causes small dispersed form metal fills die virtually gas added advantage greater strength unlike standard die heat treated process performed aluminium lead heated direct injection heated direct injection die casting known direct injection die casting die casting die casting process forced heated heated mini lead cavity process advantages lower cost reduction scrap elimination gates runners energy conservation better surface quality slower cooling cycles semi solid semi solid die casting uses metal heated temperature region allows complex parts thinner walls
Die casting