THE THEORY OF THE

PRESSURE DIE CASTING OF

ALUMINIUM ALLOYS
Dilip Panjikar
Consultant, Pune

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
There are Various Theories For Metal Filling Die Cavity

Fig.1 : Filling of the die a) charging the container b) first phase – injection of
metal into the cavity and venting of the air

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
There are Various Theories For Metal Filling Die Cavity

Fig.1 : Filling of the die c) second and third phase filling, and application of
shrinkage compensation pressure d) extraction and ejection of the casting.

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
The Nearest to Reality L.Frommer Method

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

L.Frommer Hypothesis has been verified by high speed

Filming
It is understood that the following:
a) Form
b) Position
c) Dimensions of ingate
d) Geometric configuration of ingate
are the factors which

INFLUENCE CASTING RESULTS

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

THE ESCAPE OF AIR FROM THE CAVITY

Method & Duration of Die Cavity Filling Conditioned
By
Ability of Air in Die & Container to Escape

Incoming Air Should Push the Air in Front of It

Air Should Escape Through the Vents Designed for
This Purpose

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

TIME AND METHOD OF CAVITY FILLING

a) Does Not Have Casual Value
b) Cannot Be Fixed Arbitrarily

TO OBTAIN A GOOD CASTING THE CAVITY

SHOULD BE FILLED COMPLETELY BEFORE METAL
SOLIDIFIES IN THE DIE

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

TIME OF SOLIDIFICATION DEPENDS -

a) Solidification Range ( the Temperature
Difference Between the Beginning and
the End of Solidification of Each Alloy)
b) Temperature of Metal
c) Temperature of Die
d) Thickness of Piece

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

Solidification times of a
pressure die casting as a
function of wall thickness

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

SOLIDIFICATION OF THE METAL IN THE DIE

Peculiar characteristic of Die casting is tight
dimensional tolerances
Possible due to metallic mould (Die)
During solidification metal is unable to
shrink spontaneously
Applied pressure forces metal to adhere to walls
However some shrinkage cannot be eliminated

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
Solidification Diagram
Fig.3 : Morphological diagram of the
solidification structure of the metal inside
the metal die bt. Barycentre line : tm.
Temperature of the metal is 6700C, ts.
Temperature of die is 2000C
A. Vertical layer thickness 0.1 – 0.3 mm a
function of the thermal gradient between
the alloy and the die, very fine compact
metallic grain.
B. Dendritic zone (crystalline ramifications
proceeding from the outside towards the
inside) coarser metal grain, presence of
inter- dendritic voids and porosity.
C. Thermal barycentre zone, the last to
solidify, coarse metal grain, inter-dendritic
voids between the individual crystalline
structures, porosity and formation of
shrinkage cavities.
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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

SOLIDIFICATION OF THE METAL IN THE DIE

Some Shrinkage Cannot Be Eliminated
This Happens With the Formation of Piping
of Internal Cavities, Flaws
Risers Are Important at This Stage
Risers Help to Eliminate or Reduce Internal
Shrinkage

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

SOLIDIFICATION OF THE METAL IN THE DIE

This Feeding Happens During Solidification

Pressure Applied During Cavity Filling Cycle Has
to Be Completed Within a Tight Time Frame
The Filling Time Is Decisive in Obtaining Sound
High Quality Castings

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

EXTRACTION OF THE CASTING

When casting has solidified & is dimensionally
suitable
Extraction from die die should be done in
shortest possible time
Temperature at the time of extraction should be
350oC to 250oC

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

EXTRACTION OF THE CASTING

Cooling Time Required Determines Production
Rate
Cooling Time Must Be As Brief As Possible
If Extraction Is at a Temperature Higher Than
Optimal- Brittleness - Distortion & Flaws Could
Occur
If Too Cold Extraction Will Be Difficult

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

FOR EASY EXTRACTION

a) Provide Adequate Draft in Dies & Pins

b) Draft Required Is Based on

Functionality of Piece & Thickness
c) Use Sufficient Lubrication

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
DIE LUBRICATION
Required for Casting Extraction
Lubrication Film Should Be Thin to Avoid
Dimensional Variations in Castings
Lubricant Should Remain Its Characteristics
After Contact With Molten Metal
Normally Used Materials Are -
1) Graphite 2) Aluminium Oxides 3) Talc
Dispersed in Water, Grease, Oils, Waxes

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

SUMMARY OF CHARACTERISTICS FOR A GOOD

LUBRICANT

* Allow the Extraction of the Piece From the Die.

* Prevent, With Its Screening Function, the
Welding of the Metal to the Die (Sticking, Erosions)
* Facilitate the Filling of the Die Cavity.
* Act As a True Lubricant for the Moving Parts

of the Die.
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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CAUTION

The Liquid Used for Carrying the Graphite or Other

Coatings Should Evaporate Before Molten Metal
Arrives in the Die Otherwise Gas Formation Takes
Place

Gas Volumes Are High

Venting Should Be Good Otherwise Results in

Blowholes / Porosity

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS
CHARACTERISTICS OF DIE CASTING MACHINES
Constructed and Perfected to Take Account of All the
Factors That Influence the Process
FILLING OF THE DIE CAVITY
Can Be Schematically Subdivided Into the Following
Phases
a) Pre-filling of the Cavity
b) Proper Filling
c) Pressure on the Metal During the
Solidification Phase
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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

Metal Is Introduced Slowly
Piston Expels Air
Carries Metal to Ingate
Piston Speed Max 0.25 M/sec
If Exceeded - Air Is Trapped, Creating Blowholes.
Further Travel of Piston - Fills the Die
This Should Be Done in the Shortest Possible Time

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

Piston Speed Is Determined by the Quantity of Metal

to Be Introduced Into the Die

Piston Speed Would Be in the Range of

1 to 2 Meters / Sec

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

When Piston Stops

Pressure Is Exerted on the Metal

Pressure Can Be Augmented by a Pressure

Multiplier

This Pressure Is Transmitted to the Liquid Metal in

the Cavity Feeding the Piece During Solidification

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

Pressure Can Be 300 to 1000kg/mm2 Die Has to Be

Designed Accordingly

Pressure Selection Is Dependent On:

Form, Dimensions & Structural Characteristics

Satisfactory Aesthetic Appeal Could Be the Deciding

Factor for Deciding All the Above

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

SURFACE FINISH

Speed of the Jet of Metal ( Ingate Velocity)

Filling Time

Ingate Velocity Must Be 30 - 40 Meters/sec

Speed Is Determined by Ingate Section

Speed Is Also Determined by the Section and

Velocity of the Injection Piston

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

DIE CASTING STUCTURAL INTEGRITY AND AESTHETIC

APPEARANCE IS TIED TO THE FOLLOWING FACTORS

* Configuration of the Ingate,

* Thickness and Section of the Ingate

* Filling Time of the Die Cavity.

* Speed of the Metal to the Ingate.

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THE THEORY OF THE PRESSURE DIE CASTING
OF ALUMINIUM ALLOYS

CHARACTERISTICS OF DIE CASTING MACHINES

DIE CASTING STUCTURAL INTEGRITY AND AESTHETIC
APPEARANCE IS TIED TO THE FOLLOWING FACTORS

* Physical and Technological Characteristics of

the Alloy.

* Speed and Pressure of the Casting Metal.

* Relationship Between the Temperatures of the

Metal and the Die.

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