Die casting is the method used for forcing molten metal into mold cavities under

The different metals and alloys that can be used in die casting are zinc, aluminum

An aluminium alloy die casting system provides a die casting machine which has a gate

Nowadays aluminium alloy castings are manufactured in hundreds of ways by all comme Melting and metal treatment: Aluminium and aluminium alloys may be melted in various

Casting: The Process And The Tec

The Four Steps of Die Casting

What is die casting? Essentially, die casting uses steel molds called dies which molten m

There are four key steps in the process of die casting, and each must be fully completed

1) Spray the mold with lubricant and close it. This helps to regulate the temperature insid

2) Inject the molten metal into the die. The metal is inserted at an extremely high pressur

3) Cool the mold, and wait for the metal to solidify. In some cases, the mold may be imm 4) Open the die and remove the solid cast!

Casting: The Process And The Tec

The Life of a Die

There are several secondary steps which may need to be taken once the casting is remo

A die casting die is built to do several things, each of equal importance, and quite often t Hydraulic presses can be used to remove the flash or scrap, while an older technique is

Die casting machines can apply a clamping force that ranges from 100 to 4,000 psi, and

Die casting dies typically have a lengthy lifespan, however over the course of several hu

What about Die casting?

Die casting is used by industrial foundries and manufacturers to create

The name Die Casting comes from the molds which are called dies. Th

Die casting is perfect for anyone that needs to make a lot of the same

There are two types of machines used in the Die Cast procedure. Thes

The Hot-chamber machine melts the alloy and feeds it into a section o

The Cold-chamber is used for metals that can not be used by the Hot-

The advantages of using Die casting vary but the most noticeable adva

Die casting is commonly used to create commercial goods as it yields a

Everyone should try die casting at least once if they can afford the init

Process

Die casting is the method used for forcing molten metal into mold cavities under high pre

The different metals and alloys that can be used in die casting are zinc, aluminum, coppe

There are namely two equipments used for die casting cold chamber and hot chamber p

Cold Chamber process: In the cold chamber category of die casting, a cold chamber of e

Hot Chamber process: In the hot chamber process method of die casting, the pressure th

The die casting molds which are used in this method are expensive and take usually take

Advantages of Die Casting: The method of die casting gives excellent dimensional accur Disadvantages of Die Casting: The casting weight is very less hardly between 30 grams

metal into mold cavities under high pressure. Die casting is very versatile and hence, is the widest used method for casting

n die casting are zinc, aluminum, copper, magnesium, tin and lead. Ferrous metals can also be used for die casting, die cas

asting machine which has a gate for melted aluminium alloys passage, sets a flow rate of melted aluminium alloy in range of 5m/sec to

n hundreds of ways by all commercial casting systems including green sand, dry sand, composite mould, plaster mould, investment cas

alloys may be melted in various ways. Coreless and channel induction furnaces, crucible and open-hearth reverberatory furnaces fired

And The Techniques, Part 1

molds called dies which molten metal is forced into using extremely high pressure. From steel sinks to tiny toy cars, die casting is a ver

and each must be fully completed before moving onto the next phase. However, before these steps can begin, the die worker must ensu

to regulate the temperature inside of the die, while also allowing for an easier removal of the cast object later on. The lubricant function

erted at an extremely high pressure, which allows the metal to conform to the precise shape of the die, without the dangers of lumps or a

ome cases, the mold may be immersed or sprayed with cold water to help the casting become solid faster than simply waiting for it. A hi

And The Techniques, Part 2

be taken once the casting is removed, such as removing excess metal and smoothing rough surfaces. However, die casting can create

qual importance, and quite often the die itself cannot produce a completed final product. While a die holds the liquid metal inside itself to

crap, while an older technique is to just saw off the flash by hand. A casting may need to be sanded or ground down to remove mold lin

anges from 100 to 4,000 psi, and are typically divided into categories according to the type of metals they can cast. Hot chamber dies c

ver over the course of several hundred thousand heatings and coolings, the dies' properties may begin to shift and weaken. Dies which

nd manufacturers to create practically anything and everything, such as die cast cars. Many small foundries

s which are called dies. These molds are reusable and are often made from steel but other alloys can be us

to make a lot of the same thing without any quality or pattern deviation. This is especially helpful in certain

e Die Cast procedure. These machines are essentially the same and are called the Hot-chamber and the Col

nd feeds it into a section of the machine referred to as the gooseneck. A piston then forces the alloy into th

an not be used by the Hot-chamber such as aluminum and copper. A separate furnace is needed to melt the

ut the most noticeable advantages are the repeated quality, smooth casting surface, and the quick productio

mercial goods as it yields a high volume. The molds, or dies, used vary in life cycle depending upon the ma

e if they can afford the initial cost. Besides, who knows when you'll need a small battalion of metal soldiers

into mold cavities under high pressure. Die casting is very versatile and hence, is the widest used method for casting a metal. Die cast

casting are zinc, aluminum, copper, magnesium, tin and lead. Ferrous metals can also be used for die casting, die casting method is ge

cold chamber and hot chamber process.

of die casting, a cold chamber of each module is filled with molten metal. The time exposure provided for the molten metal to plunge the

hod of die casting, the pressure that is connected to the die cavity is forever and permanently in molten metal. As the plunger moves to

e expensive and take usually take long production time. These die casting modules are also called as dies

gives excellent dimensional accuracy. The dimensional accuracy is as good as 0.1mm for the first 2.5cms and 0.005 for the first inch. D

ry less hardly between 30 grams and 10 kgs. Also the size of the material that needs to be casted using the Die Casting method needs

idest used method for casting a metal. Die casting is same as permanent mold casting the only difference is that the metal i

e used for die casting, die casting method is generally used for applications in which a large quantity is medium or small siz

inium alloy in range of 5m/sec to 15m/sec and press injects melted alloy in cavity of die. By this system it is possible to get a weldable c

uld, plaster mould, investment casting permanent mould, gravity casting, low-pressure casting and pressure die casting.

earth reverberatory furnaces fired by natural gas or fuel oil and electric resistance and electric radiation furnaces are all in routine use. T

tiny toy cars, die casting is a versatile technique that allows for various levels of complexity in production, while still maintaining absolu

n 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 m

ect later on. The lubricant functions much in the same way as household cooking spray is used on a baking pan. without the dangers of lumps or air pockets inside the product.

ster than simply waiting for it. A high pressure is maintained inside the mold, which ensures the metal doesnt change properties while in

However, die casting can create pieces of metal as thin as 1mm wide in these four simple steps, which makes it a more economic proc

olds the liquid metal inside itself to create a cast, there also must be a place for the metal to enter the die and reach the inside. This mea

r ground down to remove mold lines, and if any extra holes for screws or undercutting is necessary, this must be done outside of the die

hey can cast. Hot chamber dies can cast metals with lower melting points, such as zinc, while cold chamber dies cast metals with highe

n to shift and weaken. Dies which make castings from aluminum and its alloys tend to have a shorter lifespan, simply due to the temper

cars. Many small foundries, like the one in your garage, backyard, of workshop may find that die casting is

but other alloys can be used as long as they can withstand high pressure. The reason dies must be created

especially helpful in certain industries where quantity and quality count. Many hobbyists may have no use fo

e Hot-chamber and the Cold-chamber.

hen forces the alloy into the mold. A separate furnace is not needed but the draw back of this is that metals

nace is needed to melt the alloy which is then poured into the injection cylinder and then shot into the mold

ce, and the quick production of casts. While the initial cost of Die Casting exceeds several of the other castin

cle depending upon the material used to create the die. The die can have one cavity or several cavities depe

battalion of metal soldiers which can be made quickly and easily with die casting.

thod for casting a metal. Die casting is same as permanent mold casting the only difference is that the metal is injected into the mould a

casting, die casting method is generally used for applications in which a large quantity is medium or small sized parts are required with

or the molten metal to plunge the walls of the mold is less. This clod chamber process method is very useful for metals like aluminum, c

n metal. As the plunger moves towards the open position that is towards the non - pressurized area, the inlet port connected to the pres

cms and 0.005 for the first inch. Die casting also provides with smooth cast surfaces. Small and thin walls and can be made using the m

ng the Die Casting method needs to small say around 600mm. the process of Die Casting requires high budget and can pile up high init

nly difference is that the metal is injected into the mould at very high pressure of 10-210 Mpa. This results in a more uniform

quantity is medium or small sized parts are required with detail, good dimension and fine surface finish

m it is possible to get a weldable casting having no air. An aluminium auto part manufactured by above mentioned process is weldable a

ssure die casting.

n furnaces are all in routine use. The nature of furnace charge is as different and important as the choice of metal casting operations. T

tion, while still maintaining absolute precision to create a flawless end product.

die is still cold when the molten metal is injected, it will solidify too quickly without conforming to the correct shape. According to the siz

doesnt change properties while inside the die.

ch makes it a more economic process than using stamping presses or machine tools that require the operation of multiple pieces of larg

die and reach the inside. This means that when the metal cools, there will be small pieces of unwanted metal attached to the final cast c

is must be done outside of the die as well.

amber dies cast metals with higher melting points like aluminum.

ifespan, simply due to the temperature required to make aluminum casts, while cold chamber dies tend to last almost indefinitely. Die se

may find that die casting is really just not economical. But who said that having fun and trying new things wa

ason dies must be created from metal and not from sand or other material is due to the high amount of pre

bbyists may have no use for die casting on a practical basis but will often try at least one Die casting for the

back of this is that metals with higher melting points can not be used.

and then shot into the mold.

s several of the other casting procedures, those that need a high number of casts in the shortest amount of

ity or several cavities depending upon the need.

metal is injected into the mould at very high pressure of 10-210 Mpa. This results in a more uniform part, usually good dimensional acc

mall sized parts are required with detail, good dimension and fine surface finish.

useful for metals like aluminum, copper and metals that easily alloy with iron at high temperatures.

he inlet port connected to the pressurizing cylinder is uncovered.

alls and can be made using the method of die casting walls as tiny as 0.75mm approximately can be casted. Inserts like thread insert, h

h budget and can pile up high initial cost. Die Casting method makes the metal porous up to some extent. In the Die Casting method th

This results in a more uniform part, usually good dimensional accuracy and also good surface finish.

mentioned process is weldable and also dense in structure. The result is auto parts formed of die-cast products are produced on a larg

ce of metal casting operations. The furnace charge may differ from pre-alloyed ingot of high quality to charge made up of low quality sc

orrect shape. According to the size of the intended cast, heating can take anywhere from several hours to several minutes. After the die

peration of multiple pieces of large machinery for metalwork.

d metal attached to the final cast called flash, which will need to be removed by hand or secondary machine.

d to last almost indefinitely. Die sets for casting brass objects are extremely short-lived, and need to be replaced frequently, regardless

n and trying new things was ever economical? The process of Die Casting involves a simple concept. The m

e to the high amount of pressure used to get the molten metal into the mold. If sand molds were used in a D

east one Die casting for the sake of trying.

in the shortest amount of time possibly will benefit greatly from the investment.

art, usually good dimensional accuracy and also good surface finish.

asted. Inserts like thread insert, high strength bearing surfaces and heating elements can also be inserted using the Die Casting metho

ent. In the Die Casting method the thickest section needs to be less than 13mm or 0.5 inches.

st products are produced on a large scale cost effectively.

charge made up of low quality scrap. Even under best melting and melt holding situation melted aluminium is at risk to these types of d

s to several minutes. After the die has reached the right temperature for the job, casting can begin.

e replaced frequently, regardless of the strength of the cast.

s a simple concept. The molten metal is injected with high pressure into the mold or mold cavities. The mol

and molds were used in a Die casting procedure then the mold would crumble. There are plenty of advantag

rted using the Die Casting method. Die casting also helps in reducing or even completely eliminating the use of secondary machining o

inium is at risk to these types of degradation. a) With time at temperature, adsorption of hydrogen results in increased hydrogen conten

d or mold cavities. The mold used in die casting can have several small civilities of either the same pattern o

here are plenty of advantages of using dies in a casting procedure which makes this method desirable for an

he use of secondary machining operations. The use of Die Casting method also helps to reduce the production time and a huge numbe

ults in increased hydrogen content. b) With time at temperature, oxidation of melt occurs. c) Transient elements featured by low vapor p

f either the same pattern or different pattern.

his method desirable for anyone wishing to create a high volume of similar castings.

roduction time and a huge number of articles can be produced in a very short time. Die casting method also helps to retain as well as in

elements featured by low vapor pressure and high reactivity are reduced

d also helps to retain as well as increase the tensile strength of the metal. It offers tensile strength as high as 415 MPa that is 60ksi.

high as 415 MPa that is 60ksi.

General So, tell me a little about yourself Why are you looking (or why did you leave you last job)? What do you know about our company? What are your greatest strengths? Tell me about your greatest weakness What relevant experience do you have? Have you done anything to further your experience? Where else have you applied? what is the propotion of your current job ( shopfloor / office) ? Will ready to work 100% office what is the CTC you are expecting. Technical What are the Aluminium Parts you handle in your company Explain the process involved in HPDC . what are the press you have seen , Do you know about post casting process ( example leak testing , machining, quality control) Cost wise what is the approximate price of Aluminium ingot Rs/Kg example of any part for cycle time. cycle time for accessory bracket, oilpan , clutch housing what decides cycle time. based on weight cycle time will chage or not knowledge about investment for machines knowledge about PDL & cycle time other questions from SQ. 27000 40000 480000 Rupees Four Lac Eighty Thousand Only 576000 48000

rk 100% office