Types of Die Casting Processes

Posted by dunitzsantrino on July 29th, 2015

A metal casting process used in most manufacturing processes, die casting offers an efficient and cost-effective method to produce large volumes of high-quality products. This technique is used in the manufacture of small to mid-sized metal spare parts. Die casting is basically a simple process that involves pouring molten metal into a pre-designed cast. As the metal solidifies, it moulds into the shape of the cast, which can then be easily removed from the cast and used. The important factors that determine the quality of the finished product of die casting are the raw material, temperature, solidification time and die casting process. The two popular metal alloys used for die casting are zinc alloy and aluminium.

Let’s take a look at the different processes of die casting and how they affect the quality of finished product.

Cold-Chamber Die Casting Process

This process is commonly used for aluminium die casting. In this method, metal alloy is first melted in a furnace, and then it is manually or automatically poured into the injection system, which then passes on to the cast. It is a very slow method, which may be its only disadvantage. But, on the other hand, this technique is very effective for corrosive applications and for casting metal alloys with high melting points.

Hot-Chamber Die Casting Process

Also known as gooseneck casting, the hot-chamber die casting process is popularly used in most manufacturing units. It is called as gooseneck casting process because the technique involves the injected molten metal flowing through a gooseneck feed system into the cavity of the cast. This technique is best suited for metal alloys with high fluidity and low melting point. It is most commonly used for zinc metal casting, though other metals such as copper, lead and magnesium are also cast using this technique.

Low-Pressure Die Casting Process

This aluminium die casting technique is used when large volumes of parts have to be manufactured. In this process the mould is placed above the metal bath, and a riser tube connects the two. Pressure is applied in the chamber, which pushes the molten metal towards the cast on top.

Vacuum Die Casting Process

A die casting process similar to low-pressure die casting, this technique involves creating a vacuum in the cavity to force the molten metal into the riser tube and the cast placed on top. An advantage of this technique is that it prevents the formation of gas inclusions during the zinc die casting process.