The Aluminum Die Casting Process

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Others use direct acting hydraulic pressure. Safety interlock systems are used to prevent the die from opening during the casting cycles. Die casting machines, large or small, vary fundamentally only in the method used to inject molten metal into the die. These are classified and described as either hot or cold chamber die casting machines.

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In die casting, there are two different ways of manufacturing components: hot chamber and cold chamber die casting. In both manufacturing processes, the mold is sprayed with a release agent prior to the casting process in order to ensure that the subsequently cast part can be easily remover from the mold. However, the melt is not poured directly into the mold cavity, but is first filled into the casting chamber of the die casting machine.

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From there, the alloy is pressed into the mold by a piston (the so-called casting set) through one or more channels. The difference between the two processes lies in the structure of the casting chamber as described below. In die casting, non-ferrous metals are used to manufacture components, and the choice of alloy for a particular application depends on budget, weight and material properties.

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Various processes are used in foundry practice. Castings can also be produced without high pressure. In the sand casting process, for example, the alloy is poured into a mold made of sand, which must be destroyed in order to reveal the manufactured component (lost foam). In investment casting, which is used to manufacture very small cast parts, the molds and models (usually made of wax or plastic) are also destroyed after the casting process.

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Another example is Gravity Die Casting, which uses a permanent metal mold but does not use high pressure to press the melt into the mold. Rather, the casting is manufactured or the mold filled by gravity.

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Low pressure die casting primarily uses alloys with low melting points. It is possible to cast components from 2 to 150 kg. The advantages are that very high strength values and complex geometries as well as improved material utilization and dimensional accuracy can be achieved.

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In high pressure die casting, the melt is pressed into the mold under high pressure and at high speed, thus accelerating the casting cycle. In addition, thinner-walled castings (minimum wall thickness of 1 mm) with smoother surfaces can be produced.

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