Die casting is a metal casting process characterized by the use of a mold cavity to apply high pressure to the molten metal. Molds are usually machined from higher strength alloys, some of which are similar to injection molding.
Most die castings are iron-free, such as zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys and alloys thereof. Depending on the type of die casting, a cold chamber die casting machine or a hot chamber die casting machine is required.
The traditional die casting process consists of four steps, or is called high pressure die casting. These four steps include mold preparation, filling, injection, and falling sand, which are also the basis for various improved die casting processes.
In the preparation process, it is necessary to spray a lubricant into the cavity. In addition to helping to control the temperature of the mold, the lubricant can also help the mold to be demolded, and then the mold can be closed. The molten metal is injected into the mold with a high pressure, which is in the range of about 10 to 175 MPa.
When the molten metal is filled, the pressure is maintained until the casting solidifies. Then the push rod will push out all the castings. Since there may be multiple cavities in one mold, multiple castings may be produced during each casting process.
The process of falling sand requires separation of debris, including mold openings, runners, gates, and flash. This process is usually done by extruding the casting through a special dressing die. Other sand falling methods include sawing and sanding. If the gate is relatively fragile, you can directly drop the casting, which saves manpower. Excess mold openings can be reused after melting, with a typical yield of approximately 67%.
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