Die Casting Operation Explained Step by Step

 

Die Casting is an advanced metal-casting process that involves the injection of molten metal alloy into a cavity under high pressure. A typical die casting operation has several steps involved. Regardless, the total time required to complete these steps is very short.

You can divide the Die Casting Process into six steps. They are,

  • Melting Alloy: There are many guidelines to follow for melting alloys properly. We usually use non-ferrous metal alloys for die casting, and each type of alloy requires a specific temperature.
  • Die Preparation: We clean the two die halves are thoroughly, then lubricate, and clamp them together properly before injecting the molten metal. A sprayer mechanism cleans any residue left from the previous casting cycle and lubricates the surface to aid the next cycle.
  • Injection: Molten metal is injected into the die cavity under pressure. The injection mechanism and extent of pressure can vary depending on the type of alloy. We mainly use a High-pressure die casting mechanism for faster casting cycles.
  • Solidification: Then allow the molten metal to cool and solidify inside the cavity for a specific period. We determine the cooling period by several factors such as thermodynamic properties, shape, and size of the casting, etc.
  • Ejection: Once solid, the die halves are separated, and the casting is ejected from the die. However, the solidification process shrinks the casting and causes it to adhere to the die. So, a special ejection mechanism in the movable die half pushes out the casting.
  • Trimming/Machining: The molten metal in channels and sprue of the die also remains attached to the casting upon solidification. Moreover, the flash may form on the parting line of the dies. So, we have to manually cut, trim, or machine the excess material.

Spraying the Mold During Die Casting

Need an Expert Die Casting Service Provider?

You need Sunrise Metal. We are industry experts with rich experience in die casting. We use leading-edge die casting technology for maximum quality, and we aim to provide complete die casting solutions to our customers. That’s why we offer a wide range of services to complement your die casting project.

Our services include:

As you can see, our services are mainly focused on aluminum die casting. So, we use cold chamber die casting equipment for our die casting operations. Furthermore, we have two dedicated die casting plants at Kunshan and Nantong.

Our die casting parts factory is fully loaded with high-end aluminum die casting equipment from renowned brands such as Buhler, LK, Yizumi, and Toshiba. Likewise, the capacity of our equipment ranges from 280T to 1600T. So, we can deal with any castings regardless of their size.

We make plenty of investments for quality control of your parts as well. We thoroughly inspect every casting to ensure optimum quality for every part.

Our years of experience and research have enabled us to perfect our die casting operations. We invite you to take a look at our die casting capabilities. Then you can decide for yourself that why we might be the best option for your project.

Sunrise Metal Aluminum Die Casting Factory

What are the Factors Affecting the Duration of Die Casting?

Regardless of having several stages, a typical die casting cycle takes only a few seconds to a minute at most. There are a lot of factors affecting the time required for die casting. Some crucial factors are:

  • Thermodynamic properties of alloy
  • Size of casting
  • Geometric complexity
  • Wall thickness
  • Injection Method

Here, we are talking about clamping, injection, solidification, and ejection phase only. Because metal melting is a one-time process and trimming is usually done in a batch. Whereas, rest of the process is continuous.

The injection method can vary for different die casting processes. For instance, Hot chamber die casting has an automatic injection process, thus offers shorter casting cycles. On the contrary, you have to manually carry out the injection of cold chamber die casting equipment. So, cold chamber casting has a longer cycle.

Thermodynamic properties have a great impact in the cooling and solidification stage. So, die casting demands a specific type of alloy with superior thermodynamic properties. However, the size of the casting will also significantly impact the solidification rate.

Complex geometry and large wall thickness can cause inconsistent and delayed cooling, leading to delaying the solidification process. Additionally, certain geometric features can create hot zones. It can cause problems upon injecting the metal too fast.

 

How to Reduce Porosity During Die Casting?

Porosity is a very common issue in die casting. It is quite difficult to eliminate porosity in conventional die casting operations. So, some special measures are necessary to eliminate or keep the percentage of porosity to a minimum.

The following steps can help you deal with porosity in a die casting process:

Curing the molten metal

First of all, the material itself should be cured. Manufacturers often add additives while melting the metal alloys to remove gas pores from them. It can both reduce porosity and improve certain properties of the metal to increase structural integrity.

Adjusting the shot speed

Properly fine-tuning the injection or shot speed can substantially reduce porosity. Injecting the metal too fast increases turbulence, thus raises the potential to induce porosity in casting.

Modifying the geometry

Certain geometric elements can be responsible for porosity as well. Intricate details, thin walls, deep cavities have increased potential to cause porosity. So, the designer must carefully approach the important geometric aspects.

Creating vacuum inside the cavity

Finally, the best way to deal with porosity is to vacuum assist your die casting operations. It can virtually eliminate any porosity. Nowadays, many qualified die casting plants are opting to vacuum assisted die casting process. It allows us to create high-integrity casting with supreme quality.

Porosity defect in a Casting

Can You Automate the Die Casting Operations?

Yes, we can automate the die casting operations to increase production capacity. However, die casting is a modern technique, and most of the latest die casting equipment is pretty much automatic with minimum need for human assistance. Yet, metal pouring and ejection are done manually in some models.

The hot chamber process does not require manual pouring. Thus, it has a high production capacity. But, a huge drawback is that it can’t die cast aluminum. On the contrary, the manual metal pouring in the cold chamber process hampers casting speed.

Sunrise Metal has fully automated die casting equipment with robot-handled metal pouring and ejection operations. So, we can offer a seamless die casting service capable of handling large batches of castings.

 

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