Die casting is a process in which molten metal is injected into a mold cavity at high pressure. It is one of the quickest forming processes in casting Hundreds of castings can be manufactured relatively quickly with the use of only one mold.
The manufactured castings have uniform quality and the components produced through this process have low unit cost. The reusable mold used in the die casting process is called a die. Molds are usually machined from high strength alloys, some of which are similar to those used in injection molding.
Preparation and clamping of the two halves of the die. Each die unit is cleaned of debris from the previous injection cycle and then lubricated to assist part ejection. In addition to helping to remove the casting, the lubricant can be used to also control the temperature of the mold.
The molten metal, maintained at a set temperature within the furnace, is transferred into a chamber from where it can be injected into the die at high pressure.
Molten metal injected into the die will begin to cool and solidify as soon as it enters the die cavity. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed.
After a predetermined cooling time, the die halves are opened, and an ejection mechanism pushes the casting out of the die cavity. Following ejection, the die returns to the preparation stage and the cycle begins again.
Removal of excess or waste casting material. During cooling, excess material in the channels of the die will also solidify attached to the casting. Flash can also be attached – this is casting material forced into the joint seams of the die. This excess material must be trimmed from the casting either manually via cutting, sawing, or use of a trimming press.
Cold chamber die casting machines are constructed such that the casting set is located separately from the melt reservoir. To produce a component, the alloy is filled into the casting chamber and pressed into the casting mold through channels.
This process is suitable for materials with a higher melting point. For example, aluminum die casting, but also copper.
Hot chamber process machines are constructed with a casting chamber in constant 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 mold by the piston. This process is used for alloys with a low melting point, such as zinc, lead or tin.
Cold chamber die casting machines are constructed such that the casting set is located separately from the melt reservoir. To produce a component, the alloy is filled into the casting chamber and pressed into the casting mold through channels.
It uses tools with 4 perpendicular slides (in some cases up to 6 slides at angles other than 90°) to produce more complex and accurate castings. This process is used to produce small zinc alloy components at a rapid production rate.
Typical | Feasible | |
|---|---|---|
Materials | Magnesium Zinc Lead Tin Aluminum | Copper |
Quantity | 10000-1000000 | 1000-1000000 |
Tolerance | ±0.015 in | ±0.0005 in |
Surface Finish | 30-60 µin | 15-125 µin |
Max. Wall Thickness | 0.05-0.5 in | 0.015-1.5 in |
Part Size | 0.5 ounce- 500 lb | 0.5 ounce- 500 lb |
Shapes | Thin-walled: complex Solid: Cylindrical, cubic, complex | Thin-walled: complex Solid: Cylindrical, cubic, complex |
Die-cast product manufacturing is well-established and has far-reaching applications.
Any part production process which creates high-volume metal components will likely benefit from metal die casting, as well as many industrial manufacturing solutions including the automotives, aerospace and power tools sectors, etc.
As die casting and engineering specialists, the Omnidex Casting Team offers a full range of die casting services that exceed the capabilities of a typical foundry. Through die making to production engineering and QC, we can have the entire production line set up for you.
We have been working with some of the best metal casting foundries and factories for many years. These factories can produce top quality products with consistent, highly accurate dimensions and tolerances. Also, you are not limited to the capacity or capability of just one manufacturer, giving you flexible production volumes, more choice on materials and casting methods.
Omnidex use the very latest software to simulate molten metal flow during the die casting process. This advanced simulation both speeds die design and ensures a better quality end product. We can highlight feed points and identify areas where optimization is required.
Our casting designs always consider metal flow path and cooling shrinkage. Overflow wells, venting holes and cooling channels can be added to the designs to improve the casting results if issues are during the repeated simulation runs.
The die is the most important component in the casting process and therefore a critical design element requiring experienced input. The die must enable the flow of molten metal to fill cavities. Draft angles are also necessary for easy removal of the solidified casting.
More complex parts may have undercuts in the design, which require more die pieces. Omnidex dies are typically fabricated from high-grade tool steel for optimal durability and cost-effectiveness. Dies made of other special materials and alloys can also be provided if necessary.
Contact our Customer Service and let us know how we can help to catapult your next project to success.
If you are looking for metal casting services, our brochure is a great way to discover what Omnidex has to offer. You can download HERE to learn more.
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