Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould 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.
Other articles related to "die casting, die, casting":
... Sand permanent-mold, and die casting are all well developed for magnesium alloys, die casting being the most popular ... Athough magnesium is about twice as expensive as aluminum, its hot-chamber die-casting process is easier, more economical, and 40% to 50% faster than ... Casting operations often require additional precautions because of the reactivity of magnesium with sand and water in sheet, bar, extruded, or cast form, however, magnesium alloys present no real fire hazard ...
... Metal casting simulation is currently performed by Finite Element Method simulation software designed as a defect-prediction tool for the foundry engineer, in order ... different processes such as Gravity sand casting ... Gravity die casting ...
... Semi-solid die casting uses metal that is heated between its liquidus and solidus, so that it is "slushy" ...
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