Die casting is a manufacturing technique employed to create complex and precise details in metal parts. This process entails injecting molten metal into a steel die under immense pressure. Following the cooling and solidification of the metal, the component is removed from the cavity. Its capability to create intricate shapes with very small clearances makes die casting popular among diverse industries, including the automotive industry, electronics, aeronautics, and consumer goods.

What are the different stages of die casting process?

Mold Preparation (Die):

The first operation performed in the cycle is the making of the die, which, in most instances, is made from tool steel. Then it comes to the construction of the mold, which is divided into two sections, a fixed half (cover die) and a portion that moves (ejector die). These are machined with accuracy to the shape and size of the final parts.

Metal Heating:

In die casting services offered frequently used metals include aluminum, zinc, magnesium or copper. The metal selected is heated until molten to a form that can be injected into the die.

Injection of the Liquid Metal:

The molten metal is next injected at a very high pressure of between 1500 to 25000 psi into the mold cavity using very specialized machines . This makes it possible for the metal to occupy all the voids within the mold very fast and capture even the minute features. The high pressure ensures that no air bubbles or any other flaws remain inside, hence a perfectly shaped and homogenous part.

Cooling and Solidification of the Inserted Metal:

After the molten metal has filled the Mould cavity, it is allowed to cool and solidifies fully. The natural cooling occurs in a time frame of seconds to minutes based on what kind of metal is used and how big the part it is. Internal cooling channels present in the die also help in reduction of time taken for this.

Ejection of the Part:

Once the metal is cooled and solid, the movable part of the die is removed and the formed part is pushed out of the cavity with the help of ejector pins. The casted component apart from being ejected from the die will have undergone few if not all secondary processing operations like de-burring or de-flashing.

After Treatment (If Necessary):

As for the Surface Treatment, some operations like coating or machined to meet the surface finish standards are enlisted according to the part in hand.