What is die casting?
Die casting is a type of metal casting that uses the process of pressing molten metal into the two steel molds that make up the casting. Die casting is commonly used in mass production and is known for producing high-quality, consistent products. The equipment used in the die casting process generally has a higher initial cost compared to the process using sand molds. However, the daily production costs using die casting are often lower, so the cost per product is lower.
History of die casting
The die-casting process was originally designed in 1838 to make "removable type" machines (imagine giant stamps with removable letters). About 20 years later, the first patent related to the die casting process was finally obtained in 1849. When the die-casting equipment can be used in the North American market, the applicable uses are also expanded. In the 1900s, a mixture of tin and lead was used for die casting, and before using aluminum as the best choice, it would experience several different trends.
Low pressure die casting is performed using a vertical process, which can spray molten metal upward against gravity. The metal passes through the blast furnace under the piston through the shot blasting chamber and enters the two dies under low pressure. These two molds are made of aluminum alloy. One is fixed, while the other can be pulled apart so that the casting can be released from the mold once it cools. As the metal cools, the pressure in the mold remains the same to ensure uniform and accurate filling. As the metal cools, more molten metal can be added to fill any missing or shrinking cavities. The only disadvantage of low pressure is that the casting cycle is slow, but compared with high pressure die casting, this die casting process is a cheaper and simpler technology that can be automated.
When it comes to this metal casting method, high pressure die casting is a new craze. In contrast to low-pressure die casting, high-pressure die casting has a shorter casting cycle and utilizes a horizontal casting process rather than a vertical casting process. High-pressure die-casting is formed by two machine plates on both sides, which are locked together to form a mold in the middle, just like a die-cast sandwich. A piston is used to push the molten metal through the cavity at high speed and high pressure to fill the mold. After the metal has solidified, open the mold and remove the casting. Due to the expensive nature of the machine and its molds, high-pressure die castings should be reserved for mass production.
Although this new trend has accelerated the process, there are still some drawbacks in using high pressure die casting. High pressure die casting is a big investment, and low pressure die casting is a cheaper option. The process is also limited to smaller parts because the locking mechanism can only bear a certain weight. However, this has enabled people to use aluminum alloys to make lighter and stronger castings. This change has brought other industries (including automotive, aerospace, electronics and general hardware) that seek to minimize the weight of their cast parts and components. Great benefits.
Why choose vibration die casting
After the die casting process is completed, the casting is moved for further processing or quality inspection. In some cases, if the standard is not met, the casting will be sent back to the furnace for melting and recycling. This process requires a vibrating conveyor and feeder system to move the casting to where it needs to be moved.
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