Die casting is a highly pressurized metal forming method that drives molten material into a mold. It generates good dimensional precision metal products with the highest grade finish. The capacity to create numerous components makes it excellent for producing manifold products.
Die castings are created from non-ferrous elements such as copper, aluminum, magnesium, lead, pewter, and tin. There are many types of precision die casting, but we will tackle precision die casting in this article.
What is Precision Die Casting?
Precision Die Casting is perhaps the most challenging type of die casting. Unlike Cold and Hot chamber die casting, this method needs more time and effort to be precise and repeatable. Precision Die-casting needs a piece of advanced equipment and is only done by professionals.
Where Does Precision Die Casting Focuses On?
- Small engine
- Home Appliances
- Industrial Enclosure
- Renewable Energy
- Lighting and Electrical
- Other products with complicated components.
Types of Materials Used in Precision Die Casting
The kind of material used in precision die casting is determined by the final application for which it is intended. For instance, aluminum is utilized in vehicle and tractor parts for its low density and resistance to corrosion. In contrast, stainless steel has been used in surgical equipment for strength and durability.
The characterizations of metallic materials used in casting must be maintained throughout the melting process and afterward. The different types are as follows:
- Stainless Steel
- Carbon Steel
- Silicon Tombac
Why Bronze, Zinc, and Aluminum are Mostly Used in Precision Die Casting
Zinc is among the greatest and most overlooked die casting materials because it performs exceptionally well in virtually all applications. In terms of weight and material costs, zinc is only 2.3x more than aluminum; this implies that the material is utilized instead of zinc for more giant die molds.
Zinc is the simplest material to cast. It possesses a high degree of ductility and impact strength, which can be quickly polished. Zinc’s power derives from the alloying elements that make up the metal. Parts made of zinc are manufactured to extremely tight specifications. The impact resistance of alloyed zinc parts exceeds that of aluminum and others.
Due to alloys’ apparent exceptional casting flexibility, slender complementary and alternative can be achieved with widths as thin as.025 in or 65mm = leading in smaller, lightweight, and cheaper components.
The Main Steps of Precision Die Casting
Clamping is the locking process, and precautions in precision die casting. It allows the equipment to lock half of the molds during the following methods to have more accuracy.
During the injection process of precision die casting, the molten material is put in the hot manifold and the small nozzles. That is the start of molding cavities.
Precision Die Casting requires water-cooling channels to cool the mold after the process of injection takes place. Cooling will prevent the possibility of overheating and inhibition of soldering issues.
Ejection is the process of removing the material from the die casting equipment. Once ejected, it means that the work is semi-finished.
Trimming is the last part of precision die casting. This includes cutting the material to form into the right shape. This process also provides polishing and beautification for specific instances.