Pressure die casting is one of the most popular and efficient casting processes. The automotive parts as well as several different industrial tools are manufactured using pressure die casting. The Industry continues to widen as more and more high quality products are produced. In this article we delve deeper into pressure die casting, its process, uses and advantages.

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What Is Pressure Die Casting?

Pressure die casting is a process where molten metals are poured into a custom made cavity at extremely high pressures. It is an efficient process that allows mass production of the same mold since the mold itself is constructed to withstand high pressure as well as heat making it out of steel.

The Pressure Die Casting Process

The overall process consists of few main components :

Preparation of the Die: The die is prepared by cleaning and oiling it to make it smooth.

Injection: The molten aluminum or zinc or magnesium is injected into the die at very high levels.

Cooling: As soon as the die is closed and cooling starts the molten zinc metal instantly hardens.

Ejection: The completed die is turned and the inner side of the die with the metal is removed.

The final steps are all the finishing operations such as trimming, cutting the excessive edges, and polishing in order to attain the required standards.  

Uses of Pressure Die Casting  

Several industries use the pressure die casting includes:

Automotive: In the automotive industry pressure die casting is used to make parts such as engine blocks and structural parts for gearboxes.  

Consumer Electronics: Numerous electrical appliances such as mobile phones have casings that have been produced using the pressure die casting technique.  

Aerospace: Parts made out of pressure die casting are ideal for use in airplanes as they are light however strong.  

Industrial Machinery: It is used to make various equipment’s parts; tools which require high precision.  

Medical Devices: The pressure die casting method can be used to make parts of surgical equipment which are resistant to wear in addition to being sterile.

Classes of Pressure Die Casting  

There are two main types of pressure die casting:

Hot Chamber Die Casting:

Opt for metals with lower melting points for instance zinc and magnesium.

This comprises the metallic reservior that is attached to the die casting machine.  

Col Chamber Die Casting:

It is best for metals that have a hotter melting point such as aluminum and brass.

The molten liquid metal is transferred in a distinct chamber rather than being embedded directly.  

Advantages of Pressure Die Casting  

High Precision: Designers are able to create highly complex and intricate pieces, as well as work within strict tolerances.  

Efficiency: Fast and effective which makes it ideal for mass production.  

Material Versatility: The process can be used with a number of non-ferrous metals including aluminum, zinc and magnesium.  

Durability: The components made from this process are strong, and have excellent mechanical performance.

Cost-Effective: The processes allow for a minimised wastage of materials, while also cutting down the amount of secondary machining required.  

Choosing a Die Casting Partner: Important Tips

Particularly for complex projects, consider these tips when choosing a die casting provider:

Experience: Search for a manufacturer that specializes in your specific field.

Technology: Confirm that latest capabilities and technologies are employed.

Quality Control: Check if there are adequate quality control measures in place.

Material Availability: Make sure they provide the materials that are appropriate for the job requirements.

Customer Support: An active and engaged team can have a big impact on the results of the project.