Die casting refers to a process whereby molten liquid metal is pressed into a mould at high filling speed and under high pressure. The process uses metal and alloys, such as aluminium, steel, and iron, which have a low melting point. Die casting is advantageous because it can produce thousands of metal castings within a short period using one mould. Also, the process produces uniform components at a low cost compared to other manufacturing processes. This article offers insights for beginners about the die casting process.
The Die Casting Process
Before hot melt is filled into a mould cavity at high pressure, a process of spraying a release agent to the mould must occur. The release agent helps to remove the cast part from the mould quickly without damaging the cast. The next process entails pouring the hot melt into the casting chamber rather than directly into the mould cavity. Finally, a piston is used to press the melt into the mould.
Design Specifications
Before you engage a die casting expert, you need to know your casting needs. Some of the requirements include dimensions, shapes, parts to be cast, and the number of each component required. First, you need to develop the mould, from either sand or metal, for designing the desired parts. During the design phase of a metal casting mould, manufacturers should account for shape distortions during the cooling process.
Applications
Metal castings are used for various applications, both industrial and light-duty. The type of application helps to determine the choice of casting metal. Furthermore, the application informs the heat treatment method. Some of the common metals for die casting include aluminium, iron, steel, nickel or copper-based alloys. Different metals and alloys have different properties, such as heat resistance, durability and tensile strength, all of which affect the final product. Before a casting is used in harsh conditions such as cold, moisture-laden, or hot environments, it must be subjected to heat treatment to make it resilient to such conditions. Therefore, consider whether the intended application needs heat treatment, which might come at an additional cost.
Testing and Inspection
International standards are used to accept or reject castings based on quality and metal soundness. Testing and inspection ensure that the end products meet certain criteria for use in different applications. Some of the criteria used include cracks, internal strength, surface finish condition, dimensional accuracy and physical properties. Both destructive and non-destructive testing can be applied.
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