The applications of die castings in modern society

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The applications of die castings in modern society

Post  megan2008 on Thu Nov 07, 2013 12:34 am

Every aluminum die casting metal part is formed in a die. Dies are also sometimes called molds, and every mold is specially designed for shaping metal in a certain way. For stainless steel castings, which are the majority of castings, this mold is cut into two separate metal blocks; in order to form a complete mold, the tooled blocks are placed together with cavities aligned. Once the die has been created, it is sprayed with a lubricant that helps control its temperature and assists in part removal once the cast is complete. The die is then closed, and molten metal is poured into the shot sleeve and injected into the die under high pressure by a plunger. Pressure is maintained within the die until the cast has solidified, then the die is opened and ejector pins push out the solidified 'shot.' This metal piece is considered a shot until the excess material that has solidified around it during casting is removed. This excess material typically consists of sprue, gate, runners and flash that have formed in channels leading to the die mold and possibly in leakage areas between the mold cavities. The cast part is tooled and deburred to remove this excess and is sometimes put through additional secondary processes such as surface finishing, plating and CNC machining.

Die casting is a high volume, low cost means of forming relatively complex metal parts. Because this forming method does not create a uniform molecular structure or grainflow in the same way that forging and extruding processes do, die cast parts do not have high strength and often have microfractures and grainflow inconsistencies that can lead to part failure or breakage under strain, corrosion or heat stress. For this reason, die cast parts are often heat-treated and carefully tested in the casting manufacturers. There are some cases in which a die cast metal part is less appropriate for a task than a forging is. Consistently, though, die castings can be applied and relied on for their strength and durability if installed and maintained correctly. It is also important to carefully pair the correct die casting with its application; choosing the wrong metal for a die casting manufacturers can be catastrophic, particularly when it comes to engines and heavy machinery. A combination of careful design, materials selection, installation and maintenance will ensure the continued reliable operation of investment castings for many years.

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megan2008

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