The process may be a single step of a series steps depending on the complexity of the metal substance. Cast parts may range from fraction of inches to over 35 feet. It will depend on the design of mold or end product. Apart from these, it is also crucial to highlight the major metal casting processes that have been used in this industry.
The Engineering. The underlying factor here is exerting high pressure through a die. It is a key factor that distinguishes this metal fabrication process from the other metal casting procedures listed above. For instance, if we look at a process such as lost wax casting, investment casting or sand casting procedures, the underlying factor in this case is the fact that, the process depends on gravity to fill the mold.
The Cambridge Dictionary defines gravity as a natural force that attracts objects towards one another, more so that force, which makes things fall on the ground. This further reveal more properties of die casting in relation to other metal casting processes. Metal die casting process is used to produce various shapes from a number of non-ferrous metals such as brass , zinc, aluminum, magnesium and copper among other metals. It is one of those manufacturing processes with the ability to produce high detailed and accurate parts.
It is also preferred for mass production of components as opposed to other manufacturing processes. To understand the evolution of die casting, it will of great value if we explore its origin. It was during this time that a patent was awarded to Sturges in This was after the invention of a manually operated machine that was used for the casting printing type. This was before the technique was used for other metals such as aluminum and zinc in the s. Since then, there are a number of technological advancements that have been witnessed in the industry.
This include a number of metallurgical control measures that have improved the manufacturing and processing criteria. This is due to the high demand in the office equipment, sporting, toys, machinery, automotive and many other applications of dis cast parts and components.
These are companies that produce components for their own use. A good example is the GM metal casting plant in Bedford. This is mainly for the original equipment manufacturer OEM. One such company is the Chinese Company, Gatonbrass. It has focused on brass lamp, electrical, furniture, plumbing and home accents, among other parts.
So, what should we learn from this section? You should be able to distinguish die casting from other metal casting processes and a key point to note is, the process requires some induced pressure. Lastly, it has been adopted in a number of industrial setups with companies such as GM and Gatonbrass. To get insights on die casting, and the practical aspect of the process, we need to focus on the actual procedure. These die casting videos will try to give an insight on the basic factors about this manufacturing process.
Generally, this is a practical process that neither die casting technicians nor professionals must not depend on the theoretical part of it. The understanding should be based on both the theoretical aspects, watching videos and implementing the knowledge one gets. Video 1 : This is an animated version of the high pressure die casting process. Video Two : This video is essential for people who want to adopt low pressure die casting manufacturing technique.
Comparing this video and the previous one, it will be quite clear that the mechanisms and amount of pressure involved is quite different. Video 3 : This is a vital video for companies that would wish to invest in the die casting manufacturing process. Video 4 : This video illustrates how cold chamber die casting process takes place. The die cast brass parts are some of the most common parts that can be manufactured through this mechanism. In short, these are but, a few resources that can be vital when it comes to learning every aspect in the die casting process.
In fact, the other elements of the die casting process that are explained in the next chapters can have their video version for a proper understanding of the entire process. In the next section, we shall discuss various die casting examples.
These are tangible items or structures that we use or see in our daily lives. Die casting is one kind of technology that we have lived to embrace in our day-to-day activities. This is a popular manufacturing process that is used to produce a number of metal parts both for industrial and domestic applications. They are available in different configurations. These lamp parts include brass fixture body parts, necks and breaks among others.
Most lighting distributors place their orders to different lighting parts suppliers , and give the brass lamp parts order to a casting manufacturer ,this will save them a lot on cost. The cast parts may include window hardware, electrical components, bathroom fixtures and office equipment, just to mention a few. Like the other metals mentioned above, the steel cast parts also form an integral role of our lives.
This involves casting different types of steels such as stainless steel. Some of the most common components that are manufactured via this technique include valves, hydroelectric turbine wheels, tooling equipment and pumps among other parts in food, electrical and power industries. All these parts must be manufactured as per the international standards and regulations. Again, the iron casting company should be able to choose that specific metal that can meet the requirements of the end users.
These alloys contain different elements such as copper, manganese, magnesium, silicon and zinc, just to mention few. These elements exist in different proportions thus, different procedures can be used to cast the aluminum parts. These parts are used in different industries such as aerospace, electronics, plumbing and chemical industries. In summary, there are very many types of components and structured that can be manufactured through die casting.
However, some may require additional secondary operations. After this section, you should be able to list the various components or industries that depend on brass die cast components. Any Questions about this chapter?
Ask an engineer Now:. Not all metals or alloys can be die cast. This is due to the varying chemical and physical properties. As we all know, die casting involves heating the metal until it melts and forcing it under pressure into re-usable molds.
Heating a metal to a desirable melting temperature, therefore, the metal should be able to maintain its desirable haracteristics within that temperature range, otherwise, the whole process will be futile. Exerting pressure, the metal must be able to maintain the same properties when subjected to these high pressures. In this chapter, we will discuss the various materials that can be manipulated through this manufacturing technique.
This will act as a guide to enable the readers choose the right material for a specific application. Moreover, they should be able to adopt the right die casting technique based on the chemical and physical properties of the metals or alloys.
Ideally the main die casting alloys that are commonly used in industries include zinc, magnesium, tin, lead, aluminum and copper.
However, for the purpose of this eBook, we shall focus on the following key materials: zinc, aluminum, brass and steel. It is through a proper understanding of each metal or metal alloy that one will be able to choose the right material and die casting technique.
This explains the reason why they react differently when subjected to certain manufacturing processes. It is advisable to work closely with experts to establish the right material for any given application. It is vital to consider all the vital mechanical properties of those materials. The vital mechanical properties include elongation, tensile strength, hardness, impact strength and yield strength. These will be based on actual tests. It is important to understand the behavior of the metal when subjected to extreme environmental conditions.
In short, these three aspects will help you to narrow down to that specific alloy or metal that can meet the desired application requirements. This should be a perfect comparison that aims at getting the best material for die casting. The available zinc alloys can be categorized as:. These alloys are mainly used to cast components that require superior strength. This strength is due to the fact that they contain higher amount of aluminum.
Like the ZA alloys, they are known to have provide good castability and strength. Like other die casting technologies, this process involves forcing the molten zinc under high pressure into a mold cavity. Ideally, these are the basic facts that make zinc the best choice for a number of manufacturing processes.
Opting for zinc alloys should be designed for individuals who wish to achieve the following key aspects:. This is a critical aspect in the metal alloy processing industry. The zinc alloys can be die cast to any shape of choice. This is actually the main reason why it is used for both high quantity and quality production processes. This eliminates any additional machining operations that would otherwise increase the production costs. This is due to the fact that zinc alloys can be die cast to closer tolerances that other metal alloys.
A number of plumbing or machinery component are die cast. Zinc alloys can withstand very extreme pressure — as high as 60, psi. Due to its ductility, the end products are suitable for riveting, bending and crimping operations. These die cast parts possess desirable electrical conductivity. This is the main reason why they are used for electrical components such as heat sinks or any other application that requires an electromagnetic shielding.
Apart from the properties listed above, it is worth mentioning that other properties of die cast zinc parts also possess the following key features: excellent rigidity, anti-sparking, good bearing properties, easy finishing, thin wall castability, long tool life, recyclable and ease to machine. As mentioned above, the die casting process produces structures with a number of superior chemical and physical properties.
Generally, the zinc cast parts are mainly used in the following key applications:. This is due to the fact that it is easier to manufacture items that are accurate with very tight tolerances. Moreover, this is also attributed to the fact that the zinc can be manipulated to a wide range of shapes. These alloys are also used to manufacture parts that should be wear resistance with the ability to maintain high structural integrity.
This is essential in the electrical and automotive industry. The fact that zinc alloys can be used to manufacture very thin parts makes it a perfect choice for a number of consumer products, especially the consumer electronics.
In summary, as we wind up this section, there are a few things you need to note and these include:. Since aluminum was discovered over years ago, it has remained to be one of the most abundant metal. It is used for a wide range of engineering applications and it can be manipulated to any shape depending on the requirements at hand.
Apparently, die casting aluminum has proved to be environmentally and sustainable. This reduces the amount of waste in the environment. In fact, it is a non-ferrous metal that is commonly die cast in the world today. This is basically due to the intrinsic physical and chemical properties of aluminum. This is the main reason why it has been adopted globally. To decide whether to use aluminum alloys for a particular application, you need to understand the basic physical and chemical properties.
This is actually the reason why the aluminum die cast parts are used in a number of domestic and industrial applications. This is due to the fact that it reacts with atmospheric air to form a thin oxide layer that is inert. It has an average density of 2. The aluminum alloys are some of the lightest alloys available. This implies that the die cast components can be used in applications where the overall weight of the product should be reduced as much as possible.
Aluminum has an oxidation no. It as free electrons that can conduct electricity and thermal energy. This is the main reason why the die cast aluminum parts can be used in a number of electrical applications. This is the main reason why they are used in electrical components where these radiations may reduce or interfere with the systems performance.
Blending all the above properties together, the designers are always sure of a die cast aluminum part with superior performance. Since we have highlighted a number of applications when discussing the characteristics of these metals, we shall list the various industries and specific components that are manufactured from these alloys. Again, we need to note that there are different types of alloys optimized for different applications.
In this eBook, we shall focus on 7 different types of aluminum alloys that are die cast in most industrial setup. The K-alloy ; this aluminum allow is known to possess the following key properties: resistance to corrosion, improved cooling and zero post die casting operations. Alloy ; superior die casting properties and it possess good fluidity and guarantee better pressure tightness. Alloy ; it possesses the following key properties: dimension stability, ease of casting and good mechanical properties.
It has superior corrosion resistance too. Alloy B ; it is known for its superior wear resistance and high hardness. They are mainly used to die cast the internal combustion engine pistons. The A ; it is mainly used to cast aluminum parts where pressure tightness and fluidity is a priority. It maintains corrosion resistance and strength even at elevated temperature. Alloy A ; its properties are similar to that of the alloy A This alloy is mainly used to die cast hydraulic cylinder components.
Alloy A ; it has good thermal and mechanical properties. Its performance properties is similar to most alloys listed above. In summary, by the end of this section, you need to understand the basic properties of all the possible aluminum die casting alloys. Brass , is an alloy of mainly copper and zinc. By varying the amount of copper and zinc in the final product brass , we are able to obtain different types of brass alloys.
Normally, these metals may not provide the desired performance properties of brass, thus, other metal elements can be added. In this section, we shall focus on the main properties that we need to consider when we want to choose brass alloy for any given applications. With this information, we should be make the right decision as far as choosing the right metal is concerned.
This is an important property of brass. Metals that are cumbersome to die cast will result in high production cost.
It is important to note that brass is not inherently easy to machine. Lead is a perfect choice for this application since it has a low melting point than both copper and zinc.
A good example is the dezincification resistant DZR brass. It will remain effective and reliable even in harsh environmental conditions. This is the main reason why the die cast brass parts are used in plumbing systems with high temperature or high concentration of chloride. Die casting these parts require careful manufacturing process. This is crucial when it comes to balancing the desired metal elements.
This implies that less energy will be required to melt and subsequently process it to obtain the desired shapes. The brass parts that have been die cast are used to make door knobs, window locks, flowers vases, bearings, etc. The brass cast parts are extensively used in a number of electrical, musical instruments and plumbing applications.
Its color, which tend to resemble that of gold makes the brass die cast components resistant to tarnishing. Brass is generally soft thus, it can be used to make die cast parts that do not require friction. These include bearings and fittings.
Tin also serves the same purpose. A reason why it is a perfect choice for the brass parts used in water applications such as the naval brasses. It is due to the fact that brass is a non-ferromagnetic metal. This makes the separation process easy — by using a magnet. In summary, from these properties, you can easily examine the situation at hand and decide whether to adopt brass die cast parts of not.
There are very many types of brass alloys. This is based on the basic constituents of the alloy alongside the primary elements copper and zinc. This basically calls for critical analysis and evaluation of every aspect before deciding on a specific alloy to go for.
It is quite evident that all these variations are as a result of varying the main constituents of these metal elements. In summary, by the end of this section, you should be able to evaluate all the available types of brass alloy.
Like other metals, steel is also a common metal that can be die cast. This is due to its versatility and functionality. Again, it is also worth noting that this alloy may contain other elements that enhance its performance. It is important to note that there is clear difference between steel and either cast or wrought iron. This is mainly based on the amount of carbon content in these materials. In most cases, the percentage of carbon in steel may be between 0.
Steel may also contain other elements such as vanadium, chromium, tungsten and chromium, just to mention a few. We need to note that the physical and chemical properties of steel depend on the percentage of the constituent elements.
Again, the properties of steel are slightly different from that of iron and carbon. What are some of the desirable properties of steel? Steel is stronger than most metals that are used in engineering applications.
This strength is determined by the carbon content in the alloy. A die cast steel part with higher carbon content will be both harder and stronger. The stainless steel is corrosion resistant thus, making it a perfect choice for a number of industrial applications. This include mining and chemical processing industries. It has a relatively lightweight than a number of building materials. However, the die cast aluminum parts are lighter than die cast steel parts.
The steel cast parts do not change with time even when subjected to extreme environmental conditions. That is, even when subjected to high or low temperature, it will in the long run retain its original dimensions.
Steel has free electrons thus, it conducts both heat and electricity. Steel can be recycled effectively. This reduces the amount of scrap metal in the environment. Again, it cuts the production costs making the die cast parts cheaper. It is quite clear that steel is a versatile material that can be used for a wide range of applications. This is the same scenario when we discussed zinc, brass and zinc. Again, this will also depend on the type of steel in question.
There are very many types of steel that can be die cast. The alloy steels ; these steels contain the alloying elements in varying proportions. These alloying elements include: nickel, copper, aluminum, chromium, copper and titanium.
These elements impart different properties on the alloy such as strength, corrosion resistance, strength and ability to be die cast. The tool steels ; they are mainly known for their high strength. They contain vanadium, cobalt, tungsten and molybdenum in different quantities. The carbon steel ; the die casting companies can choose from the low carbon less than 0. Basically, this classification is based on the carbon content in the alloy.
This makes it corrosion resistant. There are 3 types of stainless steel:. Again, it is also quite clear that by varying the different constituents of steel, we can achieve different properties. It is also worth noting that the choice of a given type of steel will be based on the physical properties of the type is stainless steel. Chapter 3: Types Of Die Casting In this section, we shall discuss the various types of die casting technologies used in industries. We shall focus on three main types of technologies: pressure die casting, gravity die casting and vacuum die casting.
We shall discuss the important procedures involved in these techniques, benefits and disadvantages of every process. This is an important section that will guide you whenever you want to opt for a specific process to die cast a given types of metal. The pressure die casting is suitable for high volume run parts. This manufacturing technique can produce parts with thinner wall thickness without compromising their quality.
It uses different types of die casting machines that may range between 80 ton and ton. This depends on the ultimate pressure one wishes to achieve. Of course, it will also depend on the type of metal die casting technique. This process does not depend on the force of gravity to distribute the molten metal within the mold. Instead, an external pressure must be exerted air pressure.
This force distributes the molten metal within the mold. This implies that, this process is faster and it can be used to manufacture high quality parts. The above classification depends upon the amount of pressure used in the process. Again, it is worth noting that high pressure die casting has a wide range of applications. In short, this is an overall overview of pressure die casting. So, we need to discuss the various types of metal die casting technology.
The high pressure die casting is one of the most competitive metal processing technologies used in the manufacturing industries today. At times, it may be referred to as the pressure die casting.
In this metal die casting process, the molten metal is injected in a metal die under high pressure. Normally, the process takes place under high speed and pressure. This technology has been adopted by a number of manufacturing companies.
This is due to the superior and thin walled die cast parts. It is also important to note that, this metal part manufacturing technique may not be suitable for all manufacturing processes due to the following reasons:. Again, it also worth noting that this process may be prone to porosity problems. This is the main reason why the evacuation chamber technique may be used to reduce its effects.
This is a fundamental aspect that will guarantee the success of the entire process. That is, the choice of a recommended pressure, heating temperature and weight are key issues to consider. This choice of a suitable metal is also an integral aspect. Not forgetting the efficiency of the pressure die casting machine. For instance, an efficient machine will guarantee high production rates — about castings per hour.
This will depend on the complexity of the part and the capacity of the die casting machine. This makes sustainability and suitability some of the fundamental aspects to consider. In most cases, this die casting process is mainly used to cast zinc and aluminum. These are a number of factors that makes them suitable for this process and these include their availability and the fact that they can be recycled.
The two metals can be recycled without losing their essential priorities. Normally, the specific pressure is maintained at about bar. This requires a high grade mold and high speed. This requires a high grade mold and the process should take place at a high speed with the temperature maintained at bar. In summary, by considering all the aspects mentioned above, you can decide whether this process is suitable for a given application or not.
This is yet, another die casting technique that is popular in very many industries. The surface finish of this process can be compared to that of the gravity die casting technology.
Thou, they are not actually the same. In this process, the molten metal is injected in the mold under low pressure. Generally, the die cast parts produced by the low pressure die casting are better than the gravity die casting. Again, it is important to note that they are not as good as those produced by the high pressure die casting. The technique is mainly used to die cast the low melting point alloys such as those of magnesium and aluminum.
In most cases, the pressure required to sustain the process may range between 2 and 15 psi. This pressure causes the molten metal in the furnace to rise up a tube and enter a die cavity.
In summary, the high pressure and low pressure die casting technologies share a lot manufacturing process. The mainly difference comes in the amount of pressure required. Of course, this is the only integral factor that may make the tools used to vary slightly. This could be a superior surface finish or one with a tight tolerance. From this you can decide to go for a low or high pressure die casting process. The gravity die casting is one of those processes that is popularly used for both medium and high volume production process.
Under normal circumstances, this process uses permanent mould, thus, it is easier to achieve a near net shape product. This die casting capability varies from one manufacturer to the other.
That is, there are those companies that use the automated systems whereas other use the manual systems. The gravity die casting technique has been adopted by most companies due to the fact that it reduces the production cost. A company that has all the above manufacturing techniques can always examine the project at hand and subsequently choose a technique that suits their customers. Unlike the high pressure die casting where the molten metal moves into the die due to high pressure, this die casting technique depends on gravity.
This metal parts manufacturing process is suitable for non-ferrous alloys. That is, copper, aluminum and zinc alloys. It is a manufacturing process that is mainly used to produce heavier metals sections. However, the parts are thinner as compared to those produced by sand casting. Examples of products that can be manufactured using this technique include diesel engine parts, air conditioning systems, cylinder parts and valve flow systems, just to mention a few.
In summary, it is important to note that, this process differs from the two die casting process mentioned above in the following key aspects:. Therefore, it is important to consider the above three aspects before opting for the gravity die casting as the main manufacturing process. The aspect of production cost is also an important factor to consider.
Normally, these are parts that tend to have porosity problems. This is due to the air entrapped within the casted component. Over the years, the vacuum die casting has proved to be the best way to eliminate the porosity problem. In most cases, the die is manufactured from steel in an airtight bell housing. It has two receivers — outlet top and sprue through which the molten metal enters the die and the vacuum.
The molten metal flows into the die due to pressure difference. The molten metal flows up the sprue to the die where the metal solidifies. This cycle keeps on repeating itself.
In the vacuum die casting, the desired pressure differential is controlled by varying the vacuum. This is between the molten metal and cavity. The process requires a tight control system that can be achieved during the design process. The vacuum die casting has been adopted in a number of manufacturing companies.
The automotive industries depend on this technique to produce various engine parts. NOTE: Achieving an optimized vacuum casting process can be a challenging process. Therefore, each process should be optimized. The parts are used in the automotive, aerospace, gas manufacturing and food processing industries among other industries. Some of the most common parts manufactured via this technique include oil pumps, engine cradles, brake components, transmission transfer cases, manifolds and oil filter mountings, amongst others.
Author : P. The CAFE model combines the Aircraft and aerospace applications: a Single crystal turbine blades investment cast using complex ceramic cores. This process allowed the casting of fine channels within the blade, which, with laser drilling, allowed air-cooling of Author : Uthayakumar, M. Wu, H. Fabrication of integral ceramic mold for investment casting of hollow turbine blade based on stereolithography.
Software implementing the methods is available. Examples of realistic application illustrate the potential of the BEM in acoustic simulation. Mechanical Vibration by Janusz Krodkiewski Introduction to the theory of vibrations of mechanical systems.
First part, Modelling and Analysis, is devoted to this solution that can be approximated by the linear models.
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