MANUFACTURING PROCESSES

LAB REPORT

CONTENTS:

DIE CASTING
TYPES OF DIE CASTING
PRESSURE DIE CASTING
TYPES OF PRESSURE DIE CASTING
APPLICATIONS OF PRESSURE DIE CASTING
ALLOYS BEING USED

SUBMITTED BY: MUHAMMAD AAQIB AMIN

REG.NO:2015-IM-48
SUBMITTED TO: MISS SANA EHSAN

DIE CASTING

Die casting is a permanent mold casting procedure, in which the

mold is made of metal and large number of castings are produced
from it.
The mold cavity is created using two hardened tool steel dies
which have been machined into shape and work similarly to an
injection mold during the process.

Die casting is done by two methods:

1 Gravity Die Casting/Permanent die casting

Low pressure die casting
Slush casting
2. Pressure Die Casting

Hot chamber die casting

Cold chamber die casting

PRESSURE DIE CASTING:

Pressure Die Casting is a quick, reliable and cost-effective

manufacturing process for production of high volume, metal
components that are net-shaped have tight tolerances. Basically,
the pressure die casting process consists of injecting under high
pressure a molten metal alloy into a steel mold (or tool). This gets
solidified rapidly (from milliseconds to a few seconds) to form a
net shaped component. It is then automatically extracted.
Types of Pressure Die Casting:
High Pressure Die Casting
Low Pressure Die Casting
High pressure die casting has wider application encompassing
nearly 50% of all light alloy casting production. Currently low
pressure die casting accounts for about 20% of the total
production but its use is increasing. High pressure castings are
must for castings requiring tight tolerance and detailed geometry.
As the extra pressure is able to push the metal into more detailed
features in the mold. Low pressure die casting is commonly used
for larger and non-critical parts.
High Pressure Die Casting:
Here, the liquid metal is injected with high speed and high
pressure into the metal mold. The basic equipment consists of
two vertical platens. The bolsters are placed on these platens and

this holds the die halves. Out of the two platens, one is fixed and
the other movable.
High Pressure Die Casting Process

This helps the die to open and close. A specific amount of metal is
poured into the shot sleeve and afterwards introduced into the
mold cavity. This is done using a hydraulically-driven piston. After
the metal has solidified, the die is opened and the casting
eventually removed.

HOT CHAMBER DIE CASTING:

Hot-chamber die casting, sometimes called gooseneck casting,
is the more popular of the two die casting processes. In this
process, the cylinder chamber of the injection mechanism is
completely immersed in the molten metal bath. A gooseneck
metal feed system draws the molten metal into the die cavity.
While direct immersion in the molten bath allows for quick and
convenient mold injection, it also results in increased corrosion
susceptibility.
Machine:
The hot-chamber die casting m/c consists of:

 Plunger: It is a vertical piston for pushing molten metal.

Compressed air is also used for this procedure.
Gooseneck nozzle: For squirting out metal with high velocity
and pressure.
Molten metal basin: For melting metal to provide a continuous
supply of metal.
Die: It contains a cavity of required shape.
Ejector pins: For opening the die and removing the casting
Hydraulic circuit: This operates the pressure cylinders and
automates all the process.

Process:
A die-cycle is completed in following steps:
The gooseneck is submerged in molten metal basin.
The plunger in upper position lets the molten metal flow inside.
When metal is filled in the neck; incase of air-operated m/c, it is
raised up to the die and locked in contact with the die opening.
Incase of the plunger m/c, the holes are closed to trap the molten
metal inside the neck, on the down stroke. Plunger is pushed
down by a pressure of nearly 5000 psi to inject the molten metal

into the cavity in the die. After the die is filled, metal is left to
solidify.

After solidification, pressure is removed, the die is opened and

knock-out/ejector pins are used to eject the casting out. The die is
closed and m/c becomes ready for another casting.
The runner part is removed from the casting and as casting is
very smooth so no special machining process is required.
The production rate of this process is high due to direct use

of the molten metal from the furnace.

This process is limited in its applications to low melting point
metals
That do not chemically attach the plunger and other
mechanical components.
The metals includes zinc, tin, lead, and magnesium.

THE COLD-CHAMBER DIE CASTING PROCESS:

The cold-chamber die casting process is very similar to hotchamber die casting. With a design that focuses on minimizing
machine corrosion rather than production efficiency, the melted
metal is automatically- or hand-ladled into the injection system.
This eliminates the necessity for the injection mechanism to be
immersed in the molten metal bath.
For applications that are too corrosive for the immersion design of
hot-chamber die casting, the cold-chamber process can be an
excellent alternative. These applications include the casting of
metals with high melting temperatures, such as aluminum and
aluminum alloys.
Machine:
The cold-chamber m/c consists of following parts:

 Plunger: It is a vertical or horizontal spring-piston to push the

molten metal into the die cavity.
Shot sleeve: It is a cylinder where molten metal is poured in.
Die: The two halves die is connected in front of the shot sleeve.
Ejector pins: These are used to open the die and eject the
casting out.
Hydraulic circuit: This operates the pressure cylinders and
automates of all processes.
Process:

A die-cycle is completed in following steps:

The ladle brings the molten metal from the furnace and
pours it into the shot sleeve.

 Plunger pushes the molten metal into the cavity in the die,
with a pressure of nearly 9800 psi. After the die is filled,
metal is left to solidify.
Pressure is maintained during solidification by a plunger or
compressed air.
After solidification, pressure is removed, the die is opened.
The hydraulic operated knock-out/ejector pins are used to
eject the casting out.

The die is closed and m/c becomes ready for another

casting.

The runner part is removed from the casting and as casting

is very smooth so no special machining process is required.
Lubricants must be sprayed into the cavity to prevent
sticking.
Venting holes and passageways must be built into the dies
at the parting line to evacuate the air and gasses in the
cavity.
LOW PRESSURE DIE CASTING:

High quality castings, of aluminium alloys, along with magnesium

and other low melting point alloys are usually produced through
this
process.
Castings of aluminium in the weight range of 2-150 kg are a
common feature. The process works like this, first a metal die is
positioned above a sealed furnace containing molten metal. A
refractory-lined riser extends from the bottom of the die into the
molten metal. Low pressure air (15 - 100 KPa, 2- 15 psi) is then
introduced into the furnace. This makes the molten metal rise up
the tube and enter the die cavity with low turbulence. After the
metal has solidified, the air pressure is released. This makes the
metal still in the molten state in the riser tube to fall back into the
furnace. After subsequent cooling, the die is opened and the
casting
extracted.
With correct die design it is possible to eliminate the need of the
riser also. This is because of the directional freezing of the
casting. After the sequence has been established, the process
can be controlled automatically using temperature and pressure
controllers to oversee the operation of more than one die casting
machine.
Casting yield is exceptionally high as there is usually only one in
gate and no feeders.

 Low Pressure Die Casting Process

APPLICATIONS OF PRESSURE DIE CASTING:

Automotive parts like wheels, blocks, cylinder heads,

manifolds etc.

Aerospace castings.

Electric motor housings.

Kitchen ware such as pressure cooker.

Cabinets for the electronics industry.

General hardware appliances, pump parts, plumbing parts.

ALLOYS BEING USED:
FOR HOT CHAMBER DIE CASTING:
Hot-chamber die casting can be used with zinc, tin, lead,
and magnesium.
The hot-chamber process is ideal for metals that dont
readily attack and erode metal pots, cylinders, and
plungers.

 This process is limited in its applications to low melting

point metals having high fluidity.
Zinc: the easiest metal to cast; high ductility; high impact
strength; easily plated; economical for small parts; promotes
long die life.
Lead and tin: high density; extremely close dimensional
accuracy; used for special forms of corrosion resistance.
Such alloys are not used in foodservice applications for
public health reasons.
Magnesium: the easiest metal to machine; excellent
strength-to-weight ratio; lightest alloy commonly die cast.

FOR COLD CHAMBER DIE CASTING:

High melting alloys of brass, aluminum, and magnesium are

casted in cold-chamber m/c which have a high melting
point. During this process, metal is liquefied in a furnace
at extremely high temperatures and then ladled into a
cold chamber to be injected into the die.

Although cold chamber process is applicable to most of

alloys but due to ladling operation its production speed is
slow.
Aluminum: lightweight; high dimensional stability for
complex shapes and thin walls; good corrosion resistance;
good mechanical properties; high thermal and electrical
conductivity; retains strength at high temperatures
Magnesium: the easiest metal to machine; excellent
strength-to-weight ratio; lightest alloy commonly die cast.