Steps of the Die Casting Process

The die casting process may seem complicated, but it is surprisingly simple!  In fact, there are only four main steps involved in the die casting process: die preparation, filling, ejection, and shakeout.  We will outline each step so you fully understand the die casting process!

Die Preparation

Die preparation begins with misting the mold with a specialized lubricant. This preparation both assists in regulating the temperature of the die in addition to making the cavity easier to remove when the time comes.

Filling

Next, the die is closed before the liquid metal is added to the die amidst extremely high pressure. After the cavity is filled, the amount of pressure is regulated while the casting solidification happens.

Ejection

Ejection begins when the dies open.  At this point, the shot, or a group of several castings, is removed via ejector pins.

Shakeout

The final step in the die casting process is the shakeout.  This step includes detaching the scrap from the shot.  The shakeout is usually executed by utilizing a trimming die with a press.  However, that is not the only method to complete this process.  Another way to execute the shakeout process includes sawing and grinding.  If you are in need of a method that involves less manual labor, then your best option would be to tumble the shots.  

You now know the basic steps involved in the die casting process!  Though there are only four main steps in the process; it is crucial that these steps are done correctly to result in the highest quality possible for the finished product.  For example, utilizing high-pressure injection results in the die being filled as fast as possible.  This step is crucial because it ensures that the whole cavity is full prior to the casting starting to solidify.  Since the die casting process is one of the leading processes is the manufacturing industry, it is important to know the factors involved in the process.

3 FAQs about Die Casting Processes

What is involved the die casting process?

Generally, the die casting process involves inserting metal under extreme pressure inside a mold, or a die. Die casting equipment is generally categorized by tons equal to how much pressure the machine can apply onto the die. Die casting machines come in a wide range of sizes, from 400 tons to 4000 tons.

Despite the wide range of sizes, the main difference between the different die casting machines is the approach used to insert the metal into the die. The two approaches used are hot chamber and cold chamber die casting. A complete die casting process cycle can range from not even a second, when developing small parts, to a couple minutes for the creation of several pounds. The die casting process is the quickest method available for developing specific metal parts.

How does the die casting process compare to other processes?

When choosing between the die casting process and plastic molding there are a few things to consider. Die casting is used for creating tougher parts with high tolerances that have strength and endurance. Components made in the die casting process can withstand extreme temperatures.

Another option companies consider is sand casting compared to die casting. Die casting manufacturing creates components with smooth surfaces, thin walls, and close dimensions. Production using the die casting process is also faster and the cost of labor is lower than sand casting.

How do I choose the proper alloy for the die casting process?

Each metal used for die casting provides a different benefit to the component being created.

For example, zinc is the simplest metal to cast. Zinc provides top quality strength and is simple to plate. This ease of use makes zinc extremely cost effective when creating small product components. On the other hand, aluminum is lightweight, but still possesses stability for intricate shapes and thin sides. This alloy is also resistant to corrosion and high temperatures.