Since the die casting process is invented, there is a significant amount of costs that have been saved due to the precision of the process to create materials without sacrificing the life of the machines. The casting machines themselves last longer, and do create voluminous number of casted materials. This production of casted materials can easily offset the machine cost of acquisition and the maintenance needed to keep it running longer. When casting for parts, a blueprint is needed to create the complex shapes, angles, threads, and other complex features that a cast needs. The blueprint or design enables the machines to be set up properly to avoid redundancy and costly operations. When combining intricate processes into simple ones, the casting process becomes cheaper and lesser labor intensive compared to manual operations. It also minimizes human intervention during the casting process which eliminates hazards and risks in the workplace. Furthermore, casting methods using machines are more consistent when quality output is needed. They can also produce more compared to manual or semi-manual operations.
Among the casting alloys, aluminum, zinc and magnesium are often used since these materials are normally non-ferrous and their properties fit properly to the specifications and applications with which they will be used. These materials are often used in construction, building new machines, and other infrastructure projects. Not only diecastings of alloy are cost-effective, but they can also be readable recycled to create new castings or materials.
In the operation of die casting, quality control is maintained through real-time interaction of the processes control feedback from the computer and the die casting machine. This maintains the casting quality of the material with minimum intervention of the machine’s quality controllers. Microprocessors are installed to the casting machine which are connected to the mounted transducers. These microprocessors are responsible for the adjustments of machine operations in valves making sure that consistent quality is made shot after shot. Statistical machine data are also available to the process controllers for them to analyze outputs, and make further adjustments when necessary.
In an automated or computerized process monitoring, there are 3 steps that are observed to check on diecastings quality:
- Alarm Monitoring – the first step among all is the monitoring of the velocity, positions, accumulator pressures, die cylinder lockups, injection cylinder’s head and rod side, hydraulic oil temperature, and strains in tie-bars. Whenever any of these variables go out of limits, then the alarm is sounded. This makes certain that nothing is processed out of quality.
- Control – when there are certain fluctuations in any component of the machine, then automated controls are then used to make the necessary adjustments to ensure that all outputs are consistent. Computer sensors are mounted on ladles and arms to constantly check on the casting process.
- Data Acquisition – After installing the computerized machines for manufacturing die casts, data are then gathered in all steps of casting. These data are very important to check the performance of the casting machine and to make necessary manual adjustments when the need arises. This will also help maintenance engineers with their routine maintenance schedules.