by Terry Short
What is the Die Casting Process? The Die Casting Process is a metal casting process that is characterized by forcing molten metal into a mold cavity under the application of high pressure or under gravity. Because of the metal mold, the same mold can be used for producing an infinite number of castings, hence the process is also called a Permanent Mold Casting Process. The main die casting alloys are zinc, aluminum, magnesium, copper, lead and tin. Die-casting is the largest casting technique that is used to manufacture consumer, commercial and industrial products like automobiles, toys, parts of sink faucet, connector housing, gears, etc.
Die casting equipment was invented in mid-1800s for the purpose of producing movable type for the printing industry. In 1885 the Linotype machine was invented, which cast an entire line of type as a single unit, using a die casting process. It nearly completely replaced setting type by hand in the publishing industry. Other applications grew rapidly, with die casting facilitating the growth of consumer goods and appliances by greatly reducing the production cost of intricate parts in high volume.
Die casting molds are made of high-quality heat resistant steel. The production of the mold is very expensive, but several tens of thousands to over a million castings can be produced from just one tool.
Die Cast Mold
High Pressure Die Casting Machine
Low Pressure (Gravity)
Die Casting Machine
After casting, the gate risers and sprue are removed from the parts and the parts are cleaned and inspected.
Examples of typical die castings