Die-casting is similar to permanent mold casting, except in case of die casting, metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) PSI. This results in a more uniform part, generally good surface finish and good dimensional accuracy, as close as 0.2 % of casting dimension. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.
The molten metal is injected into the tooling under pressure. This results in a more homogeneous part, generally good surface finish and good dimensional accuracy, compared to that achieved using conventional casting methods. A result of this is the significant reduction in the requirement for post casting processing to achieve the required final configuration.
The process cycle has 5 main steps.
Clamping:- The cleaned and lubricated 2 halves of the die are clamped together inside the production machine.
Injection:- Of the shot (a predetermined volume) of molten metal at high pressure into the die.
Cooling:- The solidification of the shot in the die cavity adopting the desired final shape.
Ejection:- Of the casting from the die cavity.
Trimming:- The excess material from casting
Available material: Alloys of Aluminum, Magnesium, Zinc, Copper, Lead & Tin are the materials widely used in die-casting.
Most of die casting products should be processed or manufactured into components or a finished product for end using.
Available surface treatments: polishing, coating, plating, passivation, anodizing.
Main products : automobile and motorcycle engine cases, cylinder blocks, crankshafts, clutch housings ,variable transmission cases, transmission cases , oil plate, cylinder heads, timing chain covers, fuel tank, cars, trucks, boats accessories, ,rings seals,Hydraulic pneumatic elements, valve body parts,water and oil pump housings, textile machinery, electronic and lamp housings, , and other applications of die-casting aluminum products.