Connecting rod
Piston
Casting Techniques
Die Casting
Energy meter
dinkies
Electric iron base
Die Casting
Die casting is a permanent mold casting procedure, in which the mold is
made of metal and large number of castings are produced from it.
Dinky
Die Casting
Mold:
• The mold is made of special die steels.
• These steels have very high melting point and must resist very high
temperatures
Reason: As deformation due to heat can produce defective cavity,
consequently producing defective castings.
• The metal die is prepared by different machining operations.
Die Casting
• This mold is only preferred when a large no. of castings are to be prepared
Reason: This is an expensive mold.
• The die is in two halves.
• One half is fixed while other is moveable to allow the casting to be
removed.
Die Casting
Process:
Die casting is done by two methods:
1. Gravity Die Casting/Permanent die casting
2. Pressure Die Casting
Die Casting
Gravity Die Casting/Permanent die casting:
• Molten metal is poured manually under gravity (i.e. without pressure) into
a metal mold.
Eye panic snap
Motor bike body
Die Casting
Gravity Die Casting/Permanent Mold casting:
• Die casting differs from sand casting mainly in the fact that the metal mold
(die) with its high thermal conductivity causes a rapid cooling of the molten
metal.
• As a consequence of this rapid solidification, a comparatively fine-grained
and dense structure forms.
• Parts will have higher strength and lower ductility.
Die Casting
• Both ferrous and non-ferrous metals can be casted.
Die Casting
Pressure Die Casting:
Fry pan
• Molten metal is poured under pressure.
• There are two types of pressure die casting.
– Hot-Chamber die casting
– Cold-chamber die casting
Street racer
Die Casting
Die cycle:
• A cycle is a complete set of events in which one casting is produced.
– Closing the die.
– Shot: Injection of molten metal in die.
– Solidification of metal under pressure.
Automobile horn
– Opening the die.
– Ejection of casting from the die.
Die Casting
Cold-Chamber Die Casting:
• In this pressure die casting process, the basin of molten metal is not a part
of the machine.
Die Casting
• High melting point alloys of brass, aluminum, and magnesium are casted in
cold-chamber machine.
Body of toaster
Die Casting
Machine:
Plunger: It is a vertical or horizontal spring-piston to push the molten
metal into the die cavity.
• Shot sleeve: It is a cylinder where molten metal is poured in.
• Die: The two halves die is connected in front of the shot sleeve.
• Ejector pins: These are used to open the die and eject the casting out.
Die Casting
Die Casting
Furnace:
• The furnace is not a part of the machine itself.
Reason: As high temperatures are required in this process for melting high
melting point alloys.
• If this much heat is provided near the machine, it will not be feasible for the
machine.
Die Casting
Hot-Chamber Die Casting:
• In this pressure die casting process, the basin of molten metal is a part of
the m/c.
• Low melting point alloys of zinc, tin, and lead are casted in hot-chamber
machine.
• They have high fluidity and tend not to alloy with steel at their melt
temperatures.
Die Casting
Machine:
Plunger: It is a vertical piston for pushing molten metal.
• Gooseneck nozzle: It is used for squirting out metal with high velocity.
• Molten metal basin: It is for melting metal to provide a continuous supply
of metal.
• Die: It contains a cavity of required shape.
• Ejector pins: It is used for opening the die and removing the casting.
Die Casting
Die Casting