| Die-casting, by definition, is a process in which molten | | | | chamber machines or hot chamber machines. In a |
| metal is injected into metallic molds under pressure to | | | | cold chamber machine, the molten metal is poured |
| form objects. The molds, which are generally made | | | | into a "cold" cylinder that is attached to the die. A |
| of steel and referred to as "dies", can be designed to | | | | hydraulic piston seals the cylinder and forces the |
| create very detailed parts with little or no | | | | metal into the die. In a hot chamber machine, the |
| post-machining required after production. Die-casting is | | | | injection system sits in a bath of molten metal. A |
| analogous in many ways to plastic injection molding. | | | | plunger is raised to pull molten metal into the injection |
| Dies can be reused multiple times because the | | | | chamber, and then pushed to inject the molten metal |
| temperatures of the molten metal are not high | | | | into the die. The mechanism of a hot chamber |
| enough to affect the steel die. Die-cast parts are | | | | machine is much like a pneumatic bicycle pump, which |
| generally lightweight, and for this reason are often | | | | pulls air in from around the pump and injects it into a |
| used in aircraft and automobile applications. | | | | tire through the tube and fitting. |
| History of the Die-Casting Process | | | | After the casting process, the part may have flash, |
| Die-casting by pouring molten metal into a die, also | | | | or thin metal around the part where the two halves |
| known as the gravity pressure method, is a | | | | of the die come together, around it. The flash is |
| manufacturing method that has been used for | | | | removed during post-machining processes. Some |
| hundreds of years. The more modern method of | | | | die-cast parts are plated or painted after |
| pressure injection die casting was patented in the | | | | manufacture for appearance, but the surface of |
| mid-1800's to create lead printer's type. The use of | | | | die-cast parts are generally very smooth and hold |
| die-casting as a manufacturing technique exploded in | | | | fine detail. |
| the early 1900's, particularly when zinc and aluminum | | | | Examples of Die-Cast Components |
| alloys became more readily available. Today, | | | | Many plumbing fixtures, such as bathtub spouts, are |
| die-casting is a process used for a wide range of | | | | manufactured from zinc alloys using a die-casting |
| products and applications. | | | | process and then plated with a chrome coating. |
| Materials Used in Die-Casting | | | | Lightweight aircraft components can be die-cast from |
| In order to preserve the integrity of the die, and | | | | aluminum alloys. Other examples include heat sinks |
| allow it to be used for many castings, only alloys with | | | | with complex shapes and large surface areas for |
| relatively low melting temperatures can be used in | | | | electronic components, lightweight aluminum |
| the die casting process. Historically, lead and tin were | | | | automobile parts, and lighting fixtures. Die-cast parts |
| the primary materials for die-cast parts, since they | | | | require very little post-manufacturing machining, |
| could easily be melted using conventional processes. | | | | saving time and labor costs in the manufacturing |
| Today, the majority of die-cast parts are created | | | | process. |
| from aluminum or zinc alloys, but other metals such | | | | Die-casting is a manufacturing process used for a |
| as magnesium or copper can be used. Each alloy | | | | variety of applications, including toys. In the |
| delivers its own benefits, and therefore the product | | | | Napoleonic era, gravity pressure methods were used |
| requirements drive the material choice. Aluminum can | | | | to cast lead military figures. Die-cast vehicles have |
| be found in aircraft and automobile parts, while | | | | been available nearly as long as the vehicles |
| copper may be used for parts that must conduct | | | | themselves have existed. Early die cast |
| electricity. | | | | manufacturers existing at the turn of the 20th |
| Description of the Die-Casting Process | | | | century include Meccano in the United Kingdom and |
| Before casting is performed, the mold is assembled. | | | | Dowst Brothers in the United States. Companies such |
| A mold can consist of two or more parts, depending | | | | as Ertl have been producing die-cast farm vehicles |
| on the complexity of the part being fabricated. | | | | since 1945. |
| Die-casting machines are categorized as either cold | | | | |