The processes involved in die castings are definitely complex ones that necessitate expertise and experience. A die is defined as a material shaping device, while casting is defined as a manufacturing process by which a mold, which contains a hollow cavity of the desired shape, is filled with a molten metal and allowed to solidify.
Joining the two words together, die casting is defined as a manufacturing process by which a desired shape of a metal is obtained by using a mold (die).
When it comes to die castings, there are two specific types involved: the hot chamber die casting and the cold chamber die casting.
Both processes are accomplished by delivering a molten metal into a die cavity to produce the desired shape. The difference lies only on the method of preparing the injection system. The injection system is the part of the machine that carries the molten metal into the mold.
In the hot chamber process (also tagged as the gooseneck process), the cylinder chamber of the injection or the gooseneck mechanism is completely immersed in molten metal bath. As the name suggests, a hot furnace holds the molten bath, which is then processed to be injected into the injection mechanism. This allows the molten metal to be drawn right into the injection pump and right into the die cavity. This process is convenient and quick, but has increased corrosion susceptibility. This process is best suited for metals with low melting points and high fluidity. Examples of metals with low melting points and high fluidity include lead, magnesium, zinc and copper.
The cold chamber process, on the other hand, is used with high melting point alloys. Aluminum is an example of a high melting point alloy. Molten metal, which is melted in a separate furnace, is poured into the cylindrical sleeve and forced to take the shape of the die. This method eliminates the necessity for the injection mechanism to be immersed in molten bath. This method is used for applications that are too corrosive for immersion of design.
No matter what the techniques or approaches die castings have, both provide the advantage of providing complex shapes with closer tolerances. Die casting provide parts which are durable, dimensionally stable, and have the feel and appearance of quality. Die castings do not consist of separate parts, welded or fastened together, the strength is that of the material, not that of threads or welds. Economically speaking, die casting is also very useful as it can be used in a wide range of applications.
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die – http://thinkexist.com/dictionary/meaning/die/
casting – http://www.thefreedictionary.com/casting