Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Aluminum Die Casting is a method for creating aluminum parts that are well textured or smooth, and have a good surface finishing, and high dimensional stability. The reasons why aluminum is used for metal casting are as follows:
l It is lightweight and very stable for complex shapes and thin walls.
l It has high thermal and electrical conductivity.
l It has good corrosion resistance.
l It retains its strength at very high temperatures.
The aluminum die casting process can be broken down into the following 9 steps:
1. Ingots of aluminum alloys are exposed to high temperatures until they melt;
2. The two die halves are cleaned and lubricated before clamping them together;
3. The mold for the cast is prepared using two steel dies machined into the desired shape and clamped together by a die casting press;
4. The molten aluminum is then injected into the cavity at high pressures, allowing it to solidify;
5. The process of transferring the molten metal into a chamber before injection depends upon whether a cold chamber or hot chamber die casting machine is used;
6. The cold chamber die casting machines are used for casting alloys with high melting points such as aluminum, magnesium, etc. Therefore, aluminum die casting is done using a cold chamber machine in which the molten metal is ladled into the casting instead of being pumped by hydraulic cylinders;
7. The hot casting is allowed to cool down and solidify. The molten metal fills the die cavity to take up the desired shape of the die design;
8. The two die halves are separated and the casting is ejected;
9. Finally, the excess material attached to the aluminum casting is trimmed via secondary operations such as sawing, cutting, etc.
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