Article

Die Casting

Die casting is a widely used technique to inexpensively create metallic parts for a variety of applications. The process of casting has been in use for hundreds of years, but innovations in techniques and materials have improved the efficiency of the process and the quality of the final product.

Die casting by pouring melt metal into a die, also known as the gravity pressure method, is a manufacturing method that has been used for hundreds of years. Innovations in the die casting process led to an explosion of die casting for many applications in the early 1900's, particularly when zinc and aluminum alloys became more readily available.

The die casting process is used in a variety of industries. It produce high-quality metal parts with casting. When designing a part to be manufactured using a die-casting process, several considerations must be taken into die casting so that the part can be successfully fabricated.

Aluminium die casting have played significant role in development of aluminium industry Nowadays aluminium alloy casting are manufactured in hundreds of ways by all commercial casting systems including green sand, dry sand, composite mould, plaster mould, investment die casting permanent mould, gravity casting, low-pressure die casting and pressure die casting

One of the most important innovations in the die casting process was the development of the pressure injection process. One of the earliest pressure methods was squeeze casting, The squeeze casting method was first used for manufacturing axe heads.

After the innovation of pressure injection die casting and the introduction of new alloys, the die casting process remained fairly constant for many years until the introduction of the computer to the manufacturing industry. Computers are now used throughout the design and fabrication process:

• Mold Design - Digital design systems allow engineers to create and evaluate mold designs electronically, resulting in fewer prototypes and design iterations for Die Casting
• Mold Fabrication - Computer-aided manufacturing (CAM) processes and advances in tooling allow for very complex dies to be created with minimal human labor. Complex curvatures and intricate details can be machined into the mold with a CAM application controller.
• Process Automation - Computer systems can control the actual die casting process and monitor the status of the part during all portions of the manufacturing process. Systems can maintain the correct pressures during casting, monitor the temperature of the molten metal and the mold after casting, control part cooling through water channels, and determine when the part can be extracted from the mold.