Presentation Topic:

DIE CASTING
Mechanical Manufacturing - ii

Presented To :
Hafiz Muhammad Daud
 Group Members
 Umer Farooq 18MT04
 Ubaid Ur Rehman 18MT08
 Adnan javed 18MT19
 Hamza Ameer 18MT20
 Hafiz M.Shahbaz 18MT23
 Iftakhar Ahmad 18MT40
 Afzaal Ahmad 18MT44
 Outlines
 Introduction of die casting
 What is die casting
 History of die casting
 Molds of die casting
 Types of die casting
 Materials in die casting
 Low pressure vs high pressure die casting
 Fields of applications
 Advantages of die casting
 Disadvantages of die casting
 Introduction of die casting

 What is die casting and how has been progressing since the 19th century? This
and many other basics such as the use of different processes and materials are
explained in the following presentation.

 Die casting is one of the most economical and quickest forming processes. The
advantages of this production process are that hundreds of thousands of
castings can be produced relatively quickly by using just one mold. All
components produced have a uniform quality and involve relatively low unit
costs. But how exactly does the manufacturing process look like? What
materials can be used and in what areas are the castings used?. Also we discuss
about advantages and disadvantages of die casting .
Die casting is an automated casting process in which the
liquid melt is pressed into a mold under high pressure (150
to 1200 bar) and at a high filling speed (up to 540 km/h)
 What is die casting

 Die casting is an automated casting process in which the liquid

melt is pressed into a mold under high pressure (150 to 1200
bar) and at a high filling speed (up to 540 km/h). Usually  alloys
with a low melting point are used. This casting process is
particularly suitable for series and mass production of
components because, unlike sand casting, for example,
permanent metal molds are used which do not have to be
destroyed after casting. It is possible to produce large
and complex components with low wall thickness.
What is die casting
 History of die casting
The printing industry was able to greatly expand
its capabilities starting in the mid-1800s, thanks to
the invention of die casting equipment. Movable
typing machines required a large number of letters,
punctuation marks and more, all in single units.
Thanks to die casting, manufacturers sped up the
creation of these individual elements and helped
them maintain uniform sizes. This advance in
manufacturing technology helped reduce errors
and setup times for early printing machines.
After that start, die casting quickly spread to other
industries and has made our lives easier ever since.
 History of die casting
 The first die casting equipment was a small, hand-operated machine invented
in 1838 and patented in 1849. A combination of tin and lead was melted and
then poured into a steel mold — this mold was referred to as the “die.” As the
metal alloy cooled, it would take the shape of the mold and solidify. This final
element taken from the mold is the “casting.”
 For the first 30 years, die casting only served to help create type for printers.
Brooklyn’s Soss die-casting machine was the first to gain a strong nationwide
acceptance and it was also the first to be sold openly in North America.
However, starting in the early 1890s, more dies were created in a variety of
different shapes. Cash registers, phonographs, frames and other mass-
produced elements were being created through die casting as the world entered
a new century.
 New molds allowed die casting to enter almost every major industry and
provide parts for the machinery that was powering the country.
 Molds of die casting
The die casting molds, made of high-quality, heat-
resistant steel grades, consist of two halves which form a
cavity into which the liquid melt is pressed during the
casting process. The halves are located on a fixed and a
movable machine plate. During the casting process a high
pressure is applied to the mold halves, which is why the
mold is equipped with latches. In addition, certain parts of
the mold are cooled and/ or heated so that the casting
solidifies as desired. The production of the molds is very
expensive and time-consuming, but several tens of
thousands to over a million castings can be produced with
just one of them. A further advantage of the reusable
casting molds is that the melt cools down quickly.
 Types of die casting
 In die casting, there are two different ways of manufacturing
components: hot chamber and cold chamber die casting. In
both manufacturing processes, the mold is sprayed with a
release agent prior to the casting process in order to ensure
that the subsequently cast part can be easily remover from the
mold. However, the melt is not poured directly into the mold
cavity, but is first filled into the casting chamber of the die
casting machine. From there, the alloy is pressed into the mold
by a piston (the so-called casting set) through one or more
channels. The difference between the two processes lies in the
structure of the casting chamber as described below.
 Types of Die Casting
 Die casting is done by two methods:

 Gravity Die Casting/Permanent die casting

i. Slush casting
ii. Low pressure die casting
 Pressure Die Casting
i. Hot chamber die casting
ii. Cold chamber die casting
iii. Centrifugal casting
 1-Gravity Die Casting
 Gravity Die Casting is a
permanent mould casting
process, where the molten
metal is poured from a vessel
or ladle into the mould. The
mould cavity fills with no
force other than gravity, filling
can be controlled by tilting the
die.
 Types:
1. Slush die casting
2. Low pressure die casting
 1-Gravity Die Casting

i-Slush Casting:
Slush casting is a
variant of permanent molding casting to
create a hollow casting or hollow cast. In
the process the material is poured into the
mold and allowed to cool until a shell of
material forms in the mold. The
remaining liquid is then poured out to
leave a hollow shell.
 i-Slush Casting
 Advantages:
1. reusable mold and fast cooling rates.
2. Good surface finish and good surface details.
3. Slush casting I use to make hollow parts with no the use of cores.
4. The preferred thickness can achieve through pouring the left over molten metal.
5. Range of elegantly planned casting can casted for decorative and ornamental use.
 Disadvantages:
1. Casting wall thickness can vary
2. Lower melting point alloys
3. Variable wall thickness
4. Requires labor
5. Time consuming
 i-Slush Casting
  APPLICATIONS:
Some casting of pewter is cast using slush casting method.
Using pewter and other metals mainly hollow products are
casted. Decorative and ornamental objects that are casted are as
vase, bowls, candlesticks, lamps, statues, jewelery, animal
miniatures, various collectibles etc. Small objects and
components for industry like tankard handle, handles for hollow
wares, etc.
 1-Gravity Die Casting

ii-Low Pressure Die Casting:

Low-pressure die casting
(LPDC) is a common process used in foundries
today in which molten metal slowly fills the die,
reducing turbulence. Automotive applications
include wheels, as well as suspension, steering
and engine components.
 ii-Low Pressure Die Casting
 Advantages:
1. Very good strength values
2. Complex geometries possible as sand cores can be used
3. Higher material utilisation, no need for feeders
4. High dimensional accuracy
5. Whole process well-suited to automation
6. Less complicated machine and die technology
 Disadvantages:
1. Slower casting cycles
2. Minimum wall thickness approx. 3 mm (in die)
 ii-Low Pressure Die Casting
 Applications:
Low-pressure die casting (LPDC) is a common
process used in foundries today in which molten
metal slowly fills the die, reducing turbulence.
Automotive applications include wheels, as well
as suspension, steering and engine components.
 2-Pressure Die Casting

 High-pressure die casting is a process

wherein molten metal is forced, under
pressure, into a sealed mould cavity. It is
held in place by a powerful compressive
power (true die installed in hydraulics
machine) until the metal solidifies.
Following solidification, the die is released,
opened and the metal is released.
 Types:
1. Hot Chamber Die Casting
2. Cold Chamber Die Casting
3. Centrifugal casting
 2-Pressure Die Casting

i-Hot Chamber Die Casting:

A characteristic
feature of hot chamber die casting machines
is that the casting chamber is constantly in
contact with the liquid alloy. The melt passes
through a valve into the casting chamber,
where it is pressed at high speed into the
closed die casting mold by the piston. This
process is used for alloys with a low melting
point, such as zinc, lead or tin.
 i-Hot Chamber Die Casting

 Disadvantages:
1. disadvantages is that the setup requires that critical parts of the mechanical
apparatus, (such as the plunger), must be continuously submersed in molten
material.
 Advantages:
• Faster-cycling production
• Intricate cast-in detail
• Reduced porosity
• Longer die casting die life due to lower melting points
• Die design efficiencies = waste reduction
 i-Hot Chamber Die Casting
 Applications:
Hot chamber die casting
machines are primarily used for zinc,
copper, lead, and other low melting
point alloys. The injection mechanism
of a hot chamber machine is
immersed in a molten metal bath of a
metal holding furnace.
 2-Pressure Die Casting
ii-Cold Chamber
Die Casting:
With cold-chamber
die casting, metal is first heated to
achieve a molten state in a separate
furnace. The molten metal is then
transported to the casting machine where
it's fed into the machine's chamber. The
machine uses a pressurized plunger to
force the molten metal into the cavity of
the mold.
 ii-Cold Chamber Die Casting

 Disadvantages:
• its primary disadvantage is longer cycle times, due to the additional step of
transferring the molten metal from a separate furnace to the machine.

 Advantages:
• Not applicable for high melting point metals and alloys (eg. steels)
• Large parts can not be cast.
• High die cost.
• Too long lead time.
• Some gases my be entrapped in form of porosity.
 ii-Cold Chamber Die Casting

 Applications:
1. Carburetor
2. Crank case
3. Car valves
4. Fuel injectors
 2-Pressure Die Casting
iii- Centrifugal casting:
Centrifugal casting is a process that delivers components of high
material soundness. ... In the centrifugal casting process, molten metal is poured
into a preheated, spinning die. The die may be oriented either on a vertical or
horizontal axis depending on the configuration of the desired part.
 iii- Centrifugal casting
 Advantages:
1. Casting obtain elevated density, high mechanical strength and excellent grained structure
2. These casting have a directional solidification starting as of outside to inside
3. Structure of hollow interiors with no cores
4. Inclusion and impurities are lighter
5. Gates and riser are not required.
 Disadvantages:
1. Only several shapes can generate through this casting process
2. Trained labors are to be working for this process
3. Centrifugal casting need very high investments
4. An inexact diameter of inner surface of casting
5. Not every alloys can be cast in this method.
 iii- Centrifugal casting
 Applications:
Centrifugal casting
provides high material soundness
and is the metal casting process of
choice for jet engine compressor
cases, petrochemical furnace tubes,
many military and defense
components, and other applications
requiring high reliability.
 Materials in die casting
 In die casting, non-ferrous metals are used to manufacture components, and the choice of
alloy for a particular application depends on budget, weight and material properties.
 Aluminum is one of the most important materials with a share of more than 80 %,
followed by zinc and magnesium. However, copper, lead and tin can also be used. The
alloys have different properties. For example, aluminum (600°C) and magnesium
(520°C) have a high melting point, zinc (380°C) and lead (320°C) a low melting point.
 Die casting alloys offer many advantages:
 High corrosion resistance
 High strength and hardness
 High thermal conductivity
 High electrical conductivity
 Very good EMI/ RFI isolation
Raw materials for die casting
 Good processing properties
 Low-Pressure
vs
High-Pressure Die Casting

 Various processes are used in foundry practice. Castings can also

be produced without high pressure. In the sand casting process,
for example, the alloy is poured into a mold made of sand , which
must be destroyed in order to reveal the manufactured component
(lost foam). In investment casting, which is used to manufacture
very small cast parts, the molds and models (usually made of wax
or plastic) are also destroyed after the casting process. Another
example is Gravity Die Casting, which uses a permanent metal
mold but does not use high pressure to press the melt into the
mold. Rather, the casting is manufactured or the mold filled by
gravity.
 Low-Pressure
vs
High-Pressure Die Casting
 There are also differences in the die casting process. For example, there are
processes that use either high or low pressure to produce the components.
While high-pressure die casting accounts for around 50 % of light metal
casting production, low-pressure die casting only accounts for just under 20
% of total production.2
 Low pressure die casting primarily uses alloys with low melting points. It is
possible to cast components from 2 to 150 kg. The advantages are that very
high strength values and complex geometries as well as improved material
utilization and dimensional accuracy can be achieved. The process is less
suitable for very thin-walled parts, since only a minimum wall thickness of 3
mm can be obtained. It should also be mentioned that casting cycles using low
pressure die casting are slower than those under high pressure.
 Low-Pressure
vs
High-Pressure Die Casting
 In high pressure die casting, the melt is pressed into the mold under
high pressure and at high speed, thus accelerating the casting cycle.
In addition, thinner-walled castings (minimum wall thickness of 1
mm) with smoother surfaces can be produced. The disadvantage of
this manufacturing process, however, is that high operating and
investment costs are incurred, the strength values are lower and the
die casting weight is limited because it depends on the closing
force of the machine.
 Fields of applications
 Die casting is mainly used for large series production, i.e. for many
components of the same type to be cast. Despite the high pressure used during
the manufacturing process, a high casting quality is achieved. The die casting
process is particularly suitable for the production of very thin (up to 1 mm)
(lightweight) components.

 Most commonly, die cast components are manufactured for the automotive

industry, such as wheels, blocks, cylinder heads, valve blocks and manifolds.

 This sector accounts for around 84 % of the castings produced by German

foundries.The use of aluminum parts leads to a reduction in the weight of the
vehicles and thus to a reduction in fuel consumption.
 Fields of applications
  In addition, there are other industries in which die cast parts are
used:
 Aerospace
 Domestic Appliances
 Furniture
 Power Tools
 Electronics
 Machinery
 Lighting Technology
 In the future, other industries such as electromobility will be of
interest to foundries. This offers enormous potential for light metal
castings.
 Advantages of die casting
 Die casting is an efficient, economical process offering a broader range of
shapes and components than any other manufacturing technique. Parts have
long service life and may be designed to complement the visual appeal of the
surrounding part. Designers can gain a number of advantages and benefits by
specifying die cast parts.
 High-speed production – Die casting provides complex shapes within closer
tolerances than many other mass production processes. Little or no machining
is required and thousands of identical castings can be produced before
additional tooling is required.
 Dimensional accuracy and stability – Die casting produces parts that are
durable and dimensionally stable, while maintaining close tolerances. They are
also heat resistant.
 Advantages of die casting
 Strength and weight – Die cast parts are stronger than plastic injection
moldings having the same dimensions. Thin wall castings are stronger and
lighter than those possible with other casting methods. Plus, because die
castings do not consist of separate parts welded or fastened together, the
strength is that of the alloy rather than the joining process.

 Multiple finishing techniques – Die cast parts can be produced with smooth
or textured surfaces, and they are easily plated or finished with a minimum of
surface preparation.

 Simplified Assembly – Die castings provide integral fastening elements, such

as bosses and studs. Holes can be cored and made to tap drill sizes, or external
threads can be cast.
 Disadvantages of Die Casting

 Not applicable for high melting point metals and alloys

(eg. steels)
 Large parts can not be cast.
 High die cost.
 Too long lead time.
 Some gases my be entrapped in form of porosity n