DR.

BABASAHEB AMBEDKAR
TECHNOLOGICAL UNIVERSITY,
LONERE

DIE CASTING

BY
NIKHIL CHANDRAKANT PAWAR
(2130331612031)
S. Y. MECHANICAL ENGINEERING
INTRODUCTION

Die casting is a metal casting process that is characterized

by forcing molten metal under high pressure into a mold
cavity. 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. Most
die castings are made from non-ferrous metals,
specifically zinc, copper, aluminium, magnesium, lead,
pewter, and tin-based alloys. Depending on the type of
metal being cast, a hot- or cold-chamber machine is used.
HISTORY

Die casting equipment was invented in 1838 for the

purpose of producing movable type for the printing
industry. The first die casting-related patent was
granted in 1849 for a small hand-operated machine
for the purpose of mechanized printing type
production. In 1885 Ottmar Mergenthaler invented
the Linotype machine, which cast an entire line of Shibaura Machine’s Die Casting Machine
type as a single unit, using a die casting process.
CAST METAL
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin;
although uncommon, ferrous die casting is also possible.
• Zinc :- The easiest metal to cast; high ductility; high impact strength; easily plated;
economical for small parts; promotes long die life.
• Aluminium :- Lightweight; high dimensional stability for very complex shapes and
thin walls.
• Magnesium :- The easiest metal to machine; excellent strength-to-weight ratio;
lightest alloy commonly die cast.
• Copper :- Hardness; high corrosion resistance; highest mechanical properties
of alloys die cast.
• Silicon tombac :- High-strength alloy made of copper, zinc and silicon. Often
used as an alternative for investment cast steel parts.
• Lead & 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.
The material used defines the minimum section thickness and minimum draft
required for a casting as outlined in the table below. The thickest section
should be less than 13 mm (0.5 in), but can be greater.

METAL MINIMUM MINIMUM

SECTION DRAFT
Aluminium 0.89 mm 1:100 (0.6°)
Alloys (0.035 in)

Brass & 1.27 mm 1:80 (0.7°)

Bronze (0.050 in)
Magnesium 1.27 mm 1:100 (0.6°)
Alloys (0.050 in)
Zinc 0.63 mm 1:200 (0.3°)
Alloys (0.025 in)
DESIGN GEOMETRY
There are a number of geometric features to be considered when creating a
parametric model of a die casting:
1. Draft
2. Fillet
3. Parting Line
4. Bosses & Ribs
5. Holes & Windows
DRAFT
Draft is the amount of slope or taper given to cores or other parts of the die cavity to
allow for easy ejection of the casting from the die. All die cast surfaces that are parallel
to the opening direction of the die require draft for the proper ejection of the casting
from the die.[12] Die castings that feature proper draft are easier to remove from the
die and result in high-quality surfaces and more precise finished product.

Draft Angles
FILLET
Fillet is the curved juncture of two surfaces that would have otherwise met at a
sharp corner or edge. Simply, fillets can be added to a die casting to remove
undesirable edges and corners
PARTING LINE
Parting line represents the point at which two different sides of a mould come
together. The location of the parting line defines which side of the die is the
cover and which is the ejector.

Parting line
 BOSSES & RIBS
• Bosses :- Bosses are added to die castings to serve
as stand-offs and mounting points for parts that
will need to be mounted. For maximum integrity
and strength of the die casting, bosses must have
universal wall thickness.
• Ribs :- Ribs are added to a die casting to provide
added support for designs that require maximum Ribs and Bosses Design Guidelines
strength without increased wall thickness.
HOLES & WINDOWS
Holes and windows require special consideration when die casting because the
perimeters of these features will grip to the die steel during solidification. To
counteract this effect, generous draft should be added to hole and window
features.
EQUIPMENT

There are two basic types of die casting machines: hot-chamber machines and
cold-chamber machines. These are rated by how much clamping force they can
apply. Typical ratings are between 400 and 4,000 st (2,500 and 25,400 kg).
1. Hot – Chamber Die Casting
2. Cold – Chamber Die Casting
1. HOT – CHAMBER DIE CASTING

Hot-chamber die casting, also known as

gooseneck machines, rely upon a pool of
molten metal to feed the die. At the beginning
of the cycle the piston of the machine is
retracted, which allows the molten metal to
fill the “gooseneck”. The pneumatic- or
hydraulic-powered piston then forces this
metal out of the gooseneck into the die.
Schematic of a hot-chamber machine
2. COLD – CHAMBER DIE CASTING

These are used when the casting alloy cannot be used in

hot-chamber machines; these include aluminium, zinc
alloys with a large composition of aluminium,
magnesium and copper. The process for these machines
start with melting the metal in a separate furnace. Then
a precise amount of molten metal is transported to the
cold-chamber machine where it is fed into an unheated
shot chamber (or injection cylinder). This shot is then
driven into the die by a hydraulic or mechanical piston.
A schematic of a cold-chamber die casting machine
MOULD AND TOOLING
Two dies are used in die casting; one is called the “cover die half” and the other the “ejector
die half”. Where they meet is called the parting line. The cover die contains the sprue (for
hot-chamber machines) or shot hole (for cold-chamber machines), which allows the molten
metal to flow into the dies; this feature matches up with the injector nozzle on the hot-
chamber machines or the shot chamber in the cold-chamber machines. The ejector die
contains the ejector pins and usually the runner, which is the path from the sprue or shot hole
to the mould cavity. The cover die is secured to the stationary, or front, platen of the casting
machine, while the ejector die is attached to the movable platen. The mould cavity is cut into
two cavity inserts, which are separate pieces that can be replaced relatively easily and bolt
into the die halves.
The ejector die half
The cover die half
PROCESS
The following are the four steps in traditional die casting, also known as high-
pressure die casting, these are also the basis for any of the die casting variations:
1. Die Preparation
2. Filling
3. Ejection
4. Shakeout
1. DIE PREPARATION
The first step of high-pressure die casting is
mold preparation. During this initial step, the
manufacturing company applies a lubricant to
the interior walls of the mold. This is
important because the lubricant regulates the
mold’s temperature while also creating a film
between the molten metal and the mold,
thereby allowing for easier removal of the
casting.
2. FILLING
After preparing the die mold, the manufacturing
company injects it with molten metal. The mold
must be completed closed and sealed during this
step. Otherwise, it won’t be able to “accept” the
highly pressurized molten metal. Depending on
the specific application, the molten metal may be
injected into the mold at a pressure of between
1,500 to 25,000 pounds per square inch (PSI).
The mold maintains this pressure until the
molten metal has cooled and solidified.
 3. EJECTION
Next, the manufacturing company ejects the
newly made cavity from the mold. The mold
itself typically features ejector pins that, when
engaged, release the cavity. Of course, the cavity
must be solid for it to eject. If the raw metal is
still liquid, the manufacturing company must
wait for it to cool before it can eject the cavity
from the mold.
4. SHAKEOUT
The fourth and final step of high-pressure die
casting is shakeout. During this step, the
manufacturing company separates any scrap metal
from the newly created cavity. It’s not uncommon
for high-pressure die casting to produce excess
scrap metal. In other words, not all of the molten
metal is used to create the casting. Some remains
stuck inside the mold. As a result, the scrap metal
must be removed before the mold can be reused.
Inspection
After the shakeout of the casting it is inspected for defects. The most common
defects are misruns and cold shuts. These defects can be caused by cold dies,
low metal temperature, dirty metal, lack of venting, or too much lubricant.
Lubricant
Water-based lubricants are the most used type of lubricant, because of health,
environmental, and safety reasons. Unlike solvent-based lubricants, if water is
properly treated to remove all minerals from it, it will not leave any by-product
in the dies. If the water is not properly treated, then the minerals can cause
surface defects and discontinuities.
DIE CASTING DEFECTS
In die casting the most common defects are misruns and cold shuts. These
defects can be caused by cold dies, low metal temperature, dirty metal, lack of
venting, or excessive lubricant. Other possible defects are gas porosity,
shrinkage porosity, hot tears, and flow marks. Flow marks are marks left on the
surface of the casting due to poor gating, sharp corners or excessive lubricant.
1. Misrun
2. Cold Shuts
1. MISRUN

A misrun occurs when the molten

metal freezes before it reaches all
parts of the mould cavity – which
leaves a completely unfilled part of
the mould.
2. COLD SHUTS
Cold shuts occur when two relatively cold
streams of molten metal from different gates
meet and do not fuse together properly during
the casting process. This problem is visible to
the naked eye – giving the appearance of a crack
separating the two sections. Cold shuts can
either extend through part of the casting or the
entire workpiece.
TYPES OF DIE CASTING
1. Vacuum Die Casting Process
Vacuum pressure casting (VPC) is a relatively
new die casting process that delivers enhanced
strength and minimal porosity. This process is
similar to low-pressure die casting, except the
locations of the die-cast mold and molten metal
bath are reversed. The cylinder chamber can
become a vacuum, which forces the molten metal
into the mold cavity.
2. Squeeze Die Casting Process
Squeeze casting was created as a
workable solution for casting metals
and alloys with low fluidity. In this
process, the molten metal fills up an
open die, which then squeezes closed,
forcing the metal into the recessed
portions of the molding. The squeeze
casting process delivers extremely
dense products and is a complementary
process to subsequent heat-treating.
3. Semi – Solid Die Casting
Semi-solid die casting, sometimes called Thixoforming, is another process that
delivers minimal porosity and maximum density. A machine cuts the workpiece into
smaller slugs, and then heated.
ADVANTAGES OF DIE CASTING

1. Smooth surface.
2. Thinner walls can be cast.
3. High Mechanical Properties
4. Cost-Effective for Mass Production
5. 6. Rapid production rates.
APPLICATIONS OF DIE CASTING PROCESS

The applications of die casting are most suitable for casting medium-sized
parts with complex details. The technique is often performed on nonferrous
metals like magnesium, aluminum, etc. Die casting is one of the largest casting
methods that is used to manufacture consumer, commercial and industrial
products like automobiles, toys, parts of the sink faucet, connector housing,
gears, etc.
DISADVANTAGES OF DIE CASTING PROCESS

1. Easily Generate Porosity.

2. Usually Support Non-ferrous Metals Only.
3. Not Suitable for Low Production.
4. Low Die Life.
5. Large Capital Investment.
CONCLUSION

Die casting is a casting process used in the manufacturing industry to create

objects using pressurized molten metal. The metal — or alloy for that matter
— is heated and then forced into a mold cavity. As the molten metal cools, it
hardens. The solidified casting can then be removed from the mold cavity.
REFERENCES
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