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Pressure Die Casting Process

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In pressure die casting, metal is melted and forced into steel dies. The metal hardens into the desired shape. Molten metal is injected into a die cavity through a channel by movement of a plunger. After a preset solidification time, the plunger reverses direction, the part is ejected, and the machine is ready for the next cycle.

Hot Chamber
This process involves the use of a plunger which traps a certain volume of molten metal and forces it into the die cavity through a gooseneck and nozzle. After the metal has solidified in the die cavity, the plunger is withdrawn, the die opens and the casting is ejected. Metals having low melting points such as Zinc, copper, magnesium and lead are cast using Hot chamber die casting.

Cold Chamber
In this process molten metal is poured into the injection cylinder manually by a hand ladle or by an automatic ladle. The metal is forced into the die cavity at high pressures. High melting point alloys of aluminum and copper are normally cast using cold chamber die casting.

High pressure die casting
The most commonly used process is the high pressure die casting, in which molten aluminium is injected at high pressure into a metal mould by a hydraulically powered piston. The machinery needed for the process can be very costly and this high pressure die casting is only economic when used for high volume production.

Low pressure die casting
Low pressure die casting uses a die which is filled from a pressurised crucible underneath. The process is particularly suited to the production of rotationally symmetrical products such as automobile wheels.

The Process

The mould is closed and sealed. The plunger is in the upper position.
The plunger injects liquid metal through the gooseneck and along to the mould, whilst preserving static pressure with the
movement, until the material solidifies.
After casting the plunger returns to it's original position, whilst the product remains in the mould.
The product is removed from the mould by moving side ejectors.

Advantages of Pressure Die Casting

Parts without any joints can be made eliminating other processes such as welding and fastening.
Integral fastening elements such as bosses and studs can be included.
Good dimensional accuracy and detail.
No further machining required usually.
Low cost.

Specifications for Pressure Die Casting

Material: Nonferrous alloys that have low melting points: aluminum, zinc, magnesium, copper, lead, tin, silver.
Alternative machines: Mill 3-Axis, other casting methods.
Tooling: Requires custom tooling in shape of part.
Reducing costs: Minimize size, complexity and material volume.

Tags:- High Pressure Die Casting, Low Pressure Die Casting

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