FAQ related Die Casting
Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter and tin based alloys, although ferrous metal die castings are possible. The die casting method is especially suited for applications where a large quantity of small to medium sized parts are needed, ensuring precise surface quality and dimensional consistency.
History
Die casting was invented by Elisha K. Root, an inventor in the employ of Samuel W. Collins at the Collins axe-making factory in Canton, Connecticut in the 1830s.
Later on a patent was awarded to Sturges in 1849 for the first manually operated machine for casting printing type. The process was limited to printer?s type for the next 20 years
What is Die Casting?
Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with
What is Die Casting process?
The basic die casting process consists of injecting molten metal under high pressure into a steel mold called a die. Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die. Machine sizes range from 400
New Technologies
Australian researchers who have worked quietly over several years in a long-ignored area of metallurgy, have been rewarded with a startling discovery, which is set to reshape the way metals are manufactured around the world.
Designing an optimized die cast product
The information needed to develop, design, and manufacture a die cast product is available here. The first section of the menu contains new video modules covering many design and purchasing related topics.
Fundamentals of Die Casting Design
To know more about this topic please refer the link. This book is available in PDF version and in dvi Version.
New! Die Casting Coatings
Aluminum die castings are used in many modern applications. Although the raw surface of an aluminum die casting provides substantial protection,
Die Casting Process Cycle
The process cycle for die casting consists of five main stages, which are explained below. The total cycle time is very short, typically between 2 seconds and 1 minute.
Equipment
Hot chamber machines are used for alloys with low melting temperatures, such as zinc, tin, and lead. The temperatures required to melt other alloys would damage the pump, which is in direct contact with the molten metal. The metal is contained in an open holding pot which is placed into a furnace, where it is melted to the necessary temperature. The molten metal then flows into a shot chamber through an inlet and a plunger, powered by hydraulic pressure, forces the molten metal through a gooseneck channel and into the die. Typical injection pressures for a hot chamber die casting machine are between 1000 and 5000 psi.
Researchers Developing Functionally Graded Materials for Die Casting Molds
Automotive manufacturers may soon benefit from a new breed of metals ? known as functionally gradient materials ? that can withstand the high temperatures of die casting without cracking under pressure, according to a researcher at UMR.
Gravity Die Casting
Gravity Die Casting is a manufacturing process that involves pouring molten material into a permanent mold in order to produce metal parts which are built to tight tolerances.
Metal Types
In physical form, metals can be defined as substances, which have a bright luster and are good conductors of heat and electricity. They have varying degrees of density, hardness, malleability and ductility. (Malleability concerns being able to be hammered and rolled out, while ductility has to do with being drawn out, as into wire.).
Metal Finishing
Metal finishing constitutes a comprehensive range of methods that are exercised by most industries which manufacture metal parts. Generally, manufacturers execute the finishing after a metal part has been formed. Finishing can be any activity, which alters the surface of a workpiece to attain specific characteristics. Some common metal finishes include paint, lacquer, ceramic coatings, and other surface treatments.
Injecting molten metal
Injecting molten metal under high pressure into steel molds called ?dies? produce these castings. This process can provide a wide range of products because close tolerances can be consistently held and the efficiency with which metal parts can be produced.
Process
A steel die is mounted on a die cast machine. The mating die halves are locked together tight to withstand the high pressure injected molten metal.
Advantages
Die-casting is based on all the benefits that if offers over all other process
Different Services under Die Casting
Global Aluminum Die-Castings Market is Projected to Exceed 15.6 Billion Pounds
Owing to increasing demand from the automotive industry, the global aluminum die-castings market is projected to exceed 15.6 billion pounds by the year 2012.
Industrial Casting to 2011
US industrial castings demand will reach $35 billion in 2011, supported by gains in smaller markets such as aerospace and electrical/electronic equipment. Shipments of nonferrous types will accelerate, led by magnesium-based castings. Ferrous castings will continue to lose market share to nonferrous, both in value and tonnage.
Industrial Castings NEW US industry forecasts for 2011 & 2016
This study analyzes US markets for and manufacturers? shipments of industrial castings, also referred to as foundry products. Specific products covered are ferrous castings
New 'green' technologies make die castings stronger
The two new technologies ? a dynamic gating system and the 'ATM runner system' ? produce high-integrity castings with fine-grained microstructure and low porosity by improving the feed of molten metal into the casting. Both systems are suitable for use with aluminum and magnesium alloys.
Die-cast and sand-cast oil pans replaced by polyamide
The four largest polyamide oil pans that have gone into production to date are made of Ultramid A3HG7 Q17 (PA 66) from BASF and in what is called off-highway service.
Nonferrous Die-Castings (excluding Aluminum)
To view this report please refer this link
Life cycle analysis of conventional manufacturing techniques: die casting
To view this report please refer this link
Nonferrous Metal Foundry Products Manufacturing
For more information please refer this link
Report of Used Die Casting Machines
Case studies
All the case studies related to die casting industry will be published here like:
Graphite Mold Die Casting
To get more detail about this case study please refer this link
Fundamentals of Die Casting Design
Fundamentals of Die Casting Design
For more detail please refer this link http://pdfcast.org/pdf/fundamentals-of-die-casting-design
Die Casting related Links
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