Die casting
What is Die casting and How Does It Work
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
History
Die casting equipment was invented in 1838 for the purpose of producing movable type for the printing industry. The first die casting-related patent was granted in 1849 for a small hand-operated machine for the purpose of mechanized printing type production. In 1885 Ottmar Mergenthaler invented the Linotype machine, which cast an entire line of type as a single unit, using a die casting process. It nearly completely replaced setting type by hand in the publishing industry. The Soss die-casting machine, manufactured in Brooklyn, NY, was the first machine to be sold in the open market in North America. Other applications grew rapidly, with die casting facilitating the growth of consumer goods, and appliances, by greatly reducing the production cost of intricate parts in high volumes. In 1966,General Motors released the Acurad process.
Cast metal
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.The following is a summary of the advantages of each alloy:
Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
Aluminium: lightweight; high dimensional stability for very complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at moderately high temperatures.
Magnesium: the easiest metal 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; excellent dimensional stability; strength approaching that of steel parts.
Silicon tombac: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment cast steel parts.
Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance. Such alloys are not used in foodservice applications for public health reasons. Type metal, an alloy of lead, tin and antimony (with sometimes traces of copper) is used for casting hand-set type in letterpress printing and hot foil blocking. Traditionally cast in hand jerk moulds now predominantly die cast after the industrialisation of the type foundries.[clarification needed] Around 1900 the slug casting machines came onto the market and added further automation, with sometimes dozens of casting machines at one newspaper office.
As of 2008, maximum weight limits for aluminium, brass, magnesium, and zinc castings are estimated at approximately 70 pounds (32 kg), 10 lb (4.5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively.By late-2019, press machines capable of die casting single pieces over-100 kilograms (220 lb) were being used to produce aluminium chassis components for cars.
The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below. The thickest section should be less than 13 mm (0.5 in), but can be greater.
The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
History
Die casting equipment was invented in 1838 for the purpose of producing movable type for the printing industry. The first die casting-related patent was granted in 1849 for a small hand-operated machine for the purpose of mechanized printing type production. In 1885 Ottmar Mergenthaler invented the Linotype machine, which cast an entire line of type as a single unit, using a die casting process. It nearly completely replaced setting type by hand in the publishing industry. The Soss die-casting machine, manufactured in Brooklyn, NY, was the first machine to be sold in the open market in North America. Other applications grew rapidly, with die casting facilitating the growth of consumer goods, and appliances, by greatly reducing the production cost of intricate parts in high volumes. In 1966,General Motors released the Acurad process.
Cast metal
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.The following is a summary of the advantages of each alloy:
Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
Aluminium: lightweight; high dimensional stability for very complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at moderately high temperatures.
Magnesium: the easiest metal 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; excellent dimensional stability; strength approaching that of steel parts.
Silicon tombac: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment cast steel parts.
Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance. Such alloys are not used in foodservice applications for public health reasons. Type metal, an alloy of lead, tin and antimony (with sometimes traces of copper) is used for casting hand-set type in letterpress printing and hot foil blocking. Traditionally cast in hand jerk moulds now predominantly die cast after the industrialisation of the type foundries.[clarification needed] Around 1900 the slug casting machines came onto the market and added further automation, with sometimes dozens of casting machines at one newspaper office.
As of 2008, maximum weight limits for aluminium, brass, magnesium, and zinc castings are estimated at approximately 70 pounds (32 kg), 10 lb (4.5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively.By late-2019, press machines capable of die casting single pieces over-100 kilograms (220 lb) were being used to produce aluminium chassis components for cars.
The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below. The thickest section should be less than 13 mm (0.5 in), but can be greater.
| Metal | Minimum section | Minimum draft |
|---|---|---|
| Aluminium alloys | 0.89 mm (0.035 in) | 1:100 (0.6°) |
| Brass and bronze | 1.27 mm (0.050 in) | 1:80 (0.7°) |
| Magnesium alloys | 1.27 mm (0.050 in) | 1:100 (0.6°) |
| Zinc alloys | 0.63 mm (0.025 in) | 1:200 (0.3°) |
Equipment
There are two basic types of die casting machines: hot-chamber machines and cold-chamber machines.These are rated by how much clamping force they can apply. Typical ratings are between 400 and 4,000 st (2,500 and 25,400 kg).
Hot-chamber die casting
Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the “gooseneck”. The pneumatic- or hydraulic-powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that it is limited to use with low-melting point metals and that aluminium cannot be used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber machines are primarily used with zinc-, tin-, and lead-based alloys.
Cold-chamber die casting
These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace.Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. The biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine.
There are two basic types of die casting machines: hot-chamber machines and cold-chamber machines.These are rated by how much clamping force they can apply. Typical ratings are between 400 and 4,000 st (2,500 and 25,400 kg).
Hot-chamber die casting
Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the “gooseneck”. The pneumatic- or hydraulic-powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that it is limited to use with low-melting point metals and that aluminium cannot be used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber machines are primarily used with zinc-, tin-, and lead-based alloys.
Cold-chamber die casting
These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace.Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. The biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine.
Factory display
Coordinate Measuring/CMM
Swiss CNC lathe