The document discusses developments in die casting, including the use of molten metals injected under high pressure into steel molds. It notes that die casting machines are rated based on their clamping tonnage capacity. New alloys being used include aluminum, magnesium, and aluminum-lithium alloys for applications in the automotive and aerospace industries to reduce weight. Surface coatings and new ceramic composite and titanium matrix composite dies are also discussed, which provide benefits like reduced weight, increased corrosion resistance, and much longer lifetimes compared to conventional steel dies.

1. Die Casting
Developments in dies
Material Science

2. Die casting process
 Molten metal is injected under high pressure
into a steel mold (die).
– Rated in “Clamping tons”
 Amount of pressure they can exert on the die
 Capacity 400 tons to 4000 tons

3. Alloys
 Aluminum & magnesium
– Substitute for ferrous casting (automotive sector)
– Weight reduction
 Magnesium & titanium
– Automotive & Aerospace markets
 Aluminum – lithium alloys
– Meeting requirements in aircraft industry (reducing
structural weight).

4. Surface Coating

5. Ceramic composite die
 A unique nitride / nitride
– carbide matrix
– Half the weight of
conventional steel dies
& 10 times the useful
life.
– Proven stability to
molten metals, resistant
to corrosion, erosion,
oxidation, thermal
fatigue and cracking.

6. Titanium matrix composite tooling
– CermeTi
 Implemented in the form of shot sleeve or a partial liner
inserted into an existing H13 shot sleeve. (minimum 4
times cast life).

7. Titanium matrix composite tooling
– CermeTi
 Implemented in the form of shot sleeve or a partial liner
inserted into an existing H13 shot sleeve. (minimum 4
times cast life).