Dia casting and its types by alpha metal industries
Dia Casting And Its Types
By Alpha Metal Industries
The casting process is subdivided into two distinct subgroups:
1 - Expendable mold casting
(sand, plastic, shell, and investment (lost-wax technique) mouldings.)
2 - Nonexpendable mold casting
(permanent, die, centrifugal, and continuous casting).
Classification of die casting:
(a)Gravity Die Casting (also called permanent mould process)
(b)Pressure Die Casting
Aluminum Pressure Die Casting [ pressure die Casting Techniques]
[Die cast Part of automobile] [Die casting Fence fittings]
(Hot Die Casting machine)
There are two basic types of die casting machines:
(2) cold-chamber machines
(Intermediate cooling rates from melt
result in a dendritic microstructure.
Min. Draft Angle (º)
Copper alloys (Brass)
Minimum wall thicknesses and minimum draft angles for die
casting are :
Die casting materials:
•Zinc: the easiest alloy to cast; high ductility; high impact
strength; easily plated; economical for small parts; promotes
long die life.
•Aluminum: lightweight; high dimensional stability for complex
shapes and thin walls;.
•Magnesium: the easiest alloy to machine; excellent strength-
to-weight ratio; lightest alloy commonly die cast.
•Copper: high hardness; high corrosion resistance; highest
mechanical properties of alloys die cast; excellent wear
Material Silicon Copper
8.5 % 3.5 %
Fair easy to fill
11 % 4 %
Easy to fill
9.5 % 0.6 %
17 % 4.5 %
Common aluminum alloys for die casting are summarized as fol
•Excellent dimensional accuracy
•Smooth cast surfaces (1—2.5 μm rms).
•Thinner walls can be cast
•Inserts can be cast-in (such as threaded inserts, heating elements )
•Reduces or eliminates secondary machining operations.
•Rapid production rates.
• tensile strength as high as 415 MPa .
•Casting weight must be between 30 grams and 10 kg
•Casting must be smaller than 600 mm
•High initial cost.
•Limited to high-fluidity metals.
•A certain amount of porosity is common.
•Thickest section should be less than 13 mm
•A large production volume is needed to make this an economical .