Presented by:

Chandra bhan prajapati

2008AMD2934
The casting process is subdivided into two distinct subgroups:

1 - Expendable mold casting

(sand, plastic, shell, and investment (lost-wax technique) mouldings.)

2 - Nonexpendable mold casting

(permanent, die, centrifugal, and continuous casting).

Classification of die casting:

(a)Gravity Die Casting (also called permanent mould process)

(b)Pressure Die Casting

Die Casting Process Flow

(Image courtesy: wiki)

 [Pressure-die casting] [ pressure die Casting Techniques]

[Die cast Part of automobile] [Die casting Fence fittings]

(Image courtesy: wiki)

There are two basic types of die casting machines:
(1)hot-chamber machines
(2) cold-chamber machines

(Hot Die Casting machine)

(Image courtesy: wiki)

cold-die-casting machine

(Image courtesy: wiki)

Table : Capabilities of major casting processes

Attribute/proc sand investment Gravity die Pressure die

ess
Max. size Several Upto 20 kg Upto 50 kg Upto 8 kg
tons
Dim. tolerance >0.6 mm >0.1 mm >0.4 mm >.05 mm

Surface finish >200 rms >60 rms >150 rms >30 rms

Min. thickness >6 mm >1.5 mm >4.5 mm >0.8 mm

Economic Any no. >100 >500 >2500

quantity
 ( Cooling Curve for casting)
(Image courtesy: wiki)
Chvorinov's rule:

The local solidification time can be calculated using Chvorinov's rule,

which is:
Structure:

(Intermediate cooling rates from melt

result in a dendritic microstructure.

(Image courtesy: wiki)

Minimum wall thicknesses and minimum draft angles for die casting
are :

Min. Thickness
Material Min. Draft Angle ()
mm (in)

0.9 mm
Aluminum alloys 0.5

0.6 mm
Zinc alloys 0.25

1.25 mm
Copper alloys (Brass) 0.7
Die casting materials:

Zinc: the easiest alloy to cast; high ductility; high impact

strength; easily plated; economical for small parts; promotes
long die life.

Aluminum: lightweight; high dimensional stability for complex

shapes and thin walls;.

Magnesium: the easiest alloy to machine; excellent strength-

to-weight ratio; lightest alloy commonly die cast.

Copper: high hardness; high corrosion resistance; highest

mechanical properties of alloys die cast; excellent wear
resistance.
Common aluminum alloys for die casting are summarized as fol

Tensile Strength
Material Silicon Copper Properties
MPa (ksi)

AA 380 324
8.5 % 3.5 % Fair easy to fill
(UNS A03800) (47)

AA 384 331
11 % 4% Easy to fill
(UNS A03840) (48)

AA 386 317 Good corrosion

9.5 % 0.6 %
(UNS A03860) (46) resistance

AA 390 283 Good wear

17 % 4.5 %
(UNS A03900) (41) resistance
Advantages:
Excellent dimensional accuracy
Smooth cast surfaces (12.5 m rms).
Thinner walls can be cast
Inserts can be cast-in (such as threaded inserts, heating elements )
Reduces or eliminates secondary machining operations.
Rapid production rates.
tensile strength as high as 415 MPa .

Disadvantages:
Casting weight must be between 30 grams and 10 kg
Casting must be smaller than 600 mm
High initial cost.
Limited to high-fluidity metals.
A certain amount of porosity is common.
Thickest section should be less than 13 mm
A large production volume is needed to make this an economical .
THANK YOU