Die Casting: The Process And The Techniques, Part 1
Die Casting: The Process And The Techniques, Part 1
What is die casting? Essentially, die casting uses steel molds called
dies which molten metal is forced into using extremely high pressure.
From steel sinks to tiny toy cars, die casting is a versatile technique
that allows for various levels of complexity in production, while still
maintaining absolute precision to create a flawless end product.
The Four Steps of Die Casting
There are four key steps in the process of die casting, and each
must be fully completed before moving onto the next phase. However,
before these steps can begin, the die worker must ensure that the die
casting machine is at the required temperature. If the die is still
cold when the molten metal is injected, it will solidify too quickly
without conforming to the correct shape. According to the size of the
intended cast, heating can take anywhere from several hours to several
minutes. After the die has reached the right temperature for the job,
casting can begin.
1) Spray the mold with lubricant and close it. This helps to
regulate the temperature inside of the die, while also allowing for an
easier removal of the cast object later on. The lubricant functions
much in the same way as household cooking spray is used on a baking pan.
2) Inject the molten metal into the die. The metal is inserted at an
extremely high pressure, which allows the metal to conform to the
precise shape of the die, without the dangers of lumps or air pockets
inside the product.
3) Cool the mold, and wait for the metal to solidify. In some cases,
the mold may be immersed or sprayed with cold water to help the casting
become solid faster than simply waiting for it. A high pressure is
maintained inside the mold, which ensures the metal doesn’t change
properties while inside the die.
