Basic Die Casting Overview

What Is Die Casting and How Does It Work?

When molten alloy liquid is injected into the pressure chamber of a steel mold, the cavity of the mold is filled at high speed, and the alloy liquid solidifies under pressure to produce castings, the casting method is known as die casting. The key qualities of die casting that distinguish it from other casting methods are its high pressure and rapidity of operation, respectively.

Die casting production is comprised of three components: the die casting machine, the die casting alloy, and the die casting mold. Known as die casting, this process is the organic and comprehensive application of these three elements in order to consistently, rhythmically, and efficiently produce castings with good appearance, internal quality, and size that meet the requirements of drawings or agreements in accordance with those drawings or agreements.

Die Casting Mold Structure

– Steel (hot working steel) selected for die casting die: H, high-quality steel, SKD, DAC, FDAC. Die casting die is made of steel (hot working steel).

- Tooling structure includes the following components: Mold base; Mold kernel; Guide column; Guide sleeve; Thimble; Cylinder; Splitter; Gate Sleeve; Slider; Inclinated Guide Column; Oil Pressure Core Pulling.

- The following types of die processing equipment are available: milling machines (including CNC machining centers), wire cutting machines (including spark machine grinders), lathe welding machines, and repair machines.

The Most Serious Issues Facing Die Casting at the Present Time

Here are most serious issues facing die casting at the present time and problems that are most likely to arise during the production of die:

1. In non-vacuum casting conditions, the alloy liquid that is pressed into the mold is generally rapidly cooled and solidified. If the casting is done incorrectly, it is easy for defects such as pores and water marks to be introduced into the casting.

2. High-temperature heat treatment and welding are not possible for objects that are manufactured using conventional techniques.

3. It is now difficult to die cast some concave portions as well as high melting point alloy castings at the present time.

In addition, because die casting equipment is expensive, and mold manufacture takes time, it is not appropriate for single-piece or small-batch production. It is only in mass production that it can yield significant economic benefits.

How to Make a Reasonable Choice in Die Casting Alloy

(1) In terms of performance, it can meet the criteria of die castings.

(2) Low melting point, narrow crystallization temperature range, good fluidity at temperatures above the melting point, and minimal shrinkage after solidification are all characteristics of this material.

It possesses sufficient strength and flexibility at high temperatures while also having low thermal brittleness. (3) It is non-toxic.

Wear resistance, conductivity, thermal conductivity, and corrosion resistance, among other physical and chemical qualities, are important.

(5) A high level of processing performance.

The Most Frequently Occurring Defects in Die Casting Products

The following are examples of surface defects: water marks, sand holes, cold shuts (bubbles), cracks (shrinking), carbon deposits (discoloration of burrs), oxidation (oxidation of burrs), die sticking and strain.

Inadequate filling and mechanical properties are two examples of internal defects.

The third type of fault is dimensional deviation (also known as deformation).