Die casting is a process where molten non-ferrous metals are injected into a mold under high pressure to create consistent and complete mold strikes. It can produce parts of any size and shape, with aluminum being the most popular material. Die casting is commonly used in industrial settings, especially in the automotive sector.
Die casting is a process in which various metals can be cast from the molten state into a mold. These molds are called “dies” in many foundry circles. The mold is filled with typically non-ferrous metals, such as zinc and aluminum. It is filled in a high pressure application which ensures that the density of the cast material is at the desired level.
The metal is injected into a specific cavity or mold that has been created. This is then machined to create two opposing steel moulds. Once the cooling process is complete, the casting is then removed from the mold. It is then deburred or polished to create a product that has been manufactured to exact specifications.
The die casting process has evolved since its original inception to become much more efficient, both in terms of production and less waste material creation. When molten metal is injected into the mold, this shot uses between 1,500 pounds (680.39 kilograms) to over 25,000 pounds (11,339.08 kilograms) per square inch of pressure. This is to ensure that the entire mold is filled with material to create consistent and complete mold strikes. The term injection refers to each mold that is injected, as there can be multiple molds within a mold enclosure and multiple castings produced within a shot.
Die casting has long been a valuable means of producing hardened metal products, such as engines. Many other items are also cast into molds from molten states, such as cast iron pots and pans and other automobile parts. This manufacturing method has been used in industrial settings to create a multitude of different products, mainly because the casting process is capable of producing parts of any size and shape, depending on the mold that has been created for the metal to be cast or injected into.
Virtually any part needed for a specific application can be cast from almost any metal. One of the most popular, however, is aluminum. Aluminum’s low melting point and ease of machining make it an easily manipulated material to work with. This, in turn, results in a lower cost of production.
Due to the increased initial cost for die casting equipment and the ease of a die casting operation, most industrial settings that have these types of productions are done on a large or heavy production scale. This is especially true in the automotive sector. There, the bulk of many automotive engines are cast metal parts.
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