Casting Plant Die Casting

Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines - hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum). The differences between these machines will be detailed in the sections on equipment and tooling. However, in both machines, after the molten metal is injected into the dies, it rapidly cools and solidifies into the final part, called the casting.

The main benefits of the die casting process include:

High quality: Parts created through die casting deliver a long service life. High reliability: Uniformity of mass-produced parts is exceptional. Quick production: Die cast tooling requires minimal maintenance. Versatile design: Die casting can create virtually any size, part geometry, surface texture or luster. Minimal assembly: Assembly features such as studs, drill holes and bosses can be integrated into mold design.

There are three types of casting in Atlas Honda Plant: Gravity die Casting (GDC) High Pressure die Casting (HPDC) Low Pressure die casting (LPDC)

Gravity die Casting (GDC)

Gravity die casting is a simple casting process which utilizes reusable metallic moulds. The process is primarily used for simple shapes with some basic coring possible. It is mostly suited to casting light alloys but can also be used for steel and cast irons. Metal used is HS1S. The two halves of the mould are sprayed with a coating (usually silicate based) and then put together using locating pins to align the two halves and clamped. The mould is heated using gas burners prior to pouring the molten metal. The mould will typically have a runner for pouring and a riser to allow the molten metal to run through, the filling process is normally aided by spraying the mould with lubricants just prior to pouring. There is a melting furnace whose temperature is 670 degree Celsius. The coating serves two purposes: to act as a release agent that prevents the molten metal adhering to the metal die to prevent premature solidification of the molten metal Once poured the mould is allowed to cool before being opened to release the casting. Further machining will be necessary to remove any excess material and heat treatment may be required dependent on component use. Pros

Good surface texture Equipment costs are relatively low No need for applied pressure, so mould designs tend to be quite simple Scrap metal can be recycled

 Cons

Quick set up times High percentage of scrap metal High occurrence of porosity, but this can be minimized by slower pouring Only good for simple 3D shapes, cannot be used for complex shapes There are new coatings becoming available for gravity die casting that are much longer lasting than the silicate based coatings and that prevent the need for constant retouching up and extend the useful life of the moulds.

High Pressure Die Casting (HPDC)

High Pressure Die Casting provides the shortest route from molten metal to completed component. By injecting molten metal (whether it be aluminum die casting or zinc die casting) into a hardened tool steel mould and allowing it to solidify under pressure before ejection. This process allows fast, precise, cost effective production of aluminum or zinc die castings, meeting the needs of hi-tech industries where product appearance and dimensional tolerances are critical but volumes are not always large. Molten metal is thrown into the melting chamber whose temperature is 600-630 degree celcius.Raw material is feed to the melting chamber and HD2BS1. Aluminum melting point is 500 degree Celsius. High pressure die casting is used for complex shapes, Holes and High pressure. High pressure die casting is used for crank case and covers. After material is produced, it is sent to Quality Assurance Inspection from where the following tests are performed: Material Composition Analysis Physical inspection

Material composition analysis are used for testing materials Cast Iron, Carbon Steel, Alloy Steel, Stainless Steel, Tool Steel, Spring Steel, Bearing Steel, Mould Steel, Heat-resistant Steel, Special Alloy, High Manganese Steel, Nickel Alloy, Titanium alloy. It is used for refining of material and de-gassing of molten metal. Due to its high pressure argon gas is not used, instead of Nacl. Low Pressure Die Casting (LPDC) High quality castings, of aluminium alloys, along with magnesium and other low melting point alloys are usually produced through this process. Castings of aluminium in the weight range of 2-150 kg are a common feature.The process works like this, first a metal die is positioned above a sealed furnace containing molten metal. A refractory-lined riser extends from the bottom of the die into the molten metal. Low pressure air (15 - 100 kPa, 2- 15 psi) is then introduced into the furnace. This makes the molten metal rise up the tube and enter the die cavity with low turbulence. After the metal has solidified, the air pressure is released. This makes the metal still in the molten state in the riser tube to fall back into the furnace. After subsequent cooling, the die is opened and the casting extracted.

The core in LPDC is sand. LPDC is basically used for less complex structures. Surface finishing and minimum wall thickness are both better than gravity casting, but poorer than high pressure die casting.