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Different Types of Die Casting and its applications

Today I will be discussing on different types of die casting process and their applications. Previously I enlighten on what is die casting, and also examined in its advantages and disadvantages.

Working principle of a die casting

It is known to be a metal working process that is carryout by forcing metals or alloys in a mold cavity at a very high temperature. If you can recall from my previous article, die casting process is utilize when bulk metallic parts are needed.  That is, it offers fast production rate. As for the types of die casting process, there are two types; hot and cold chamber.

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Types of die casting process

Hot chamber die casting

Hot chamber is the most popular types of die casting process. it is also known as gooseneck casting. In hot chamber, the casting chamber is constantly in contact with a liquid alloy and molten metal passes through a valve into the casting chamber. Piston also plays an important role. It helps to press the molten metal in the chamber at high speed. Hot chamber types of die casting are suitable for casting metals with low melting points and fluidity e.g. copper, magnesium, zinc, tin, lead etc. one of the greatest advantages is that, the direct immersion helps to quickly transfer molten metal into mold cavity.

Hot chamber die casting process

Cold chamber die casting

In these types of die casting, immersion of the injection mechanism in the molten bath is eliminated. Molten metal is automatically or manually pour into an injection system in cold chamber. It is carryout by filling a casting chamber with alloy and pressing it to pass through channels to the die casting mold. Unlike hot chamber, cold chamber die casting is suitable for metals with higher melting point for example, aluminum and copper. This is because of corrosive nature of the metals, making it not suitable for immersion in hot chamber die casting.

Cold chamber die casting

Different variation can be implied in any of these types of die casting process when producing an item. These include:

Low pressure die casting: low pressure uses metals or alloys with low melting point. It has possibility of casting component from 2 to 150kg, offering high strength and complex geometry. It also improves dimensional accuracy and material utilization. However, low pressure die casting is not suitable for an item with tin wall, because minimum of wall thickness that can be obtain is 30mm. it is a slower process.

Advantages and disadvantages of Low pressure die casting

High-pressure die casting: it is a process in which molten metal is forced under pressure into a lock metal die cavity, where it is held by a powerful press until the metal solidifies. After solidification of the metal, the die is unlocked, opened, and the casting ejected.

Advantages and disadvantages of high die casting

Other processes include:

Vacuum  process: this process is a new process that offers good strength and minimal porosity to the casting. It is similar to low pressure die casting, except the arrangement of die casting mold and molten metal bath. Vacuum here is a cylinder chamber, which helps in forcing molten metal into a mold cavity. these types of casting is carryout on items having post-casting heat treatment uses.

Squeeze die casting: squeeze die casting is establish as a working solution for casting metals and alloys with low fluidity. It is carryout by filling molten metal in an open die. The die is squeeze closed, forcing metal into mold cavity. these types of die casting are often used for strengthening of fiber and mostly related to molten aluminum. It produces good dense product.

Semi-solid die casting: this process is also known as thixoforming. It offers maximum density and minimum porosity just as of squeeze process. Materials is cut into smaller slags before heating. After heating to a phase transition between solid and liquid, it is forced into a mold cavity. Nonferrous metals are often used e.g. magnesium alloy and aluminum alloy.

Applications

As die casting is used for large series of production. It applications in many industries such as aerospace, domestic appliances, furniture, power tools, electronics, machinery, lighting technology etc.

Die casting is also applicable in automotive industries in producing wheels, blocks, cylinder heads, valve and manifolds.

And that is it for this article, types of die casting and its application. I hope you understand. Answer the question below to assure me you truly understand. please share. Thanks for reading!

Question: Explain any one variation types of die casting can work on

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