PRESENTATION ON

DIE CASTING

BY NISAR HOSSAIN

WHAT IS DIE CASTING?

The die casting is a metal forming process
which forces molten metal under high pressure
into mould cavities.
Most die castings are made from nonferrous metals, specifically zinc,
copper, and aluminium based alloys, but ferrous metal die castings are
also possible.

The die casting method is especially suited for applications where

many small to medium sized parts are needed with good detail, fine
surface quality and dimensional consistency.

DIE CASTING PROCESS OVERVIEW

Die is closed.
Molten metal
is drawn in to die
( by plunger).

Metal solidifies
under pressure.
(cooling process)

Metal injected
into cavity by
plunger.

Cavity continues
to fill. (fractions
of a second)

Die is opened.
Machine recovers to
Casting is ejected.
initial orientation
(cycle starts over)

TYPES OF DIE CASTING

HOT CHAMBER MACHINE
MACHINE

COLD CHAMBER

DIE CASTING
ADVANTAGES

DISADVANTAGES

EXCELLENT DIMENSIONAL ACCURACY.

Casting weight must be between 30

grams and 10 kg (20 lb.)

REDUCES OR ELIMINATES SECONDARY

MACHINING OPERATIONS.

High initial cost.

RAPID PRODUCTION RATES.

A large production volume is needed

to make this an economical
alternative to other processes.

CASTING TENSILE STRENGTH IS HIGH WITH

RESPECT TO NORMAL CASTING.

Limited to high-fluidity metals.

DIE CASTING DEFECTS

DEFECT
FLASH
CAUSES:
INJECTION PRESSURE TOO
HIGH
CLAMP FORCETOO LOW
HOT TEARING
CAUSES:
NON-UNIFORM COOLING RATE
EJECTOR MARKS
CAUSES:
COOLING TIME TOO SHORT
EJECTION FORCE TOO HIGH

IMAGES

THANK YOU