DIE CASTING 1. Introduction 2. Metal Casting Processes 3. Sample Parts 4. Equipment 5. Advantages and Limitations of Die Casting 6.

Selection of Alloys 7. Die Construction 8. Process Cycle 9. Runner Design 10.Defects and Causes

DIE CASTING

INTRODUCTION

DIE CASTING

INTRODUCTION

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity, which is machined into two hardened tool steel dies. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead and tin based alloys. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high volume production.

DIE CASTING

INTRODUCTION

It is especially suited for a large quantity of small to medium sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish and dimensional consistency. The molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

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METAL CASTING PROCESSES

In metal working, casting involves pouring a liquid metal into a mould which contains a hollow cavity of the desired shape, and then is allowed to solidify, with pressure maintained during solidification. The solidified part is also known as a casting, which is ejected out of the mold to complete the process. Depending on the type of metal being cast, a hot-or coldchamber machine is used.

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METAL CASTING PROCESSES

Sand Casting Die Casting Shell Casting Plaster Casting Centrifugal Casting Squeeze Casting Ceramic Casting Investment Casting

Semi-solid Casting Single crystal Casting Lost foam Casting Pressure Casting Directional solidification Vacuum Casting Slush Casting Continuous Casting

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SAMPLE PARTS

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SAMPLE PARTS

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SAMPLE PARTS

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SAMPLE PARTS

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SAMPLE PARTS

DIE CASTING

SAMPLE PARTS

DIE CASTING

SAMPLE PARTS

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EQUIPMENT

DIE CASTING

EQUIPMENT

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EQUIPMENT

There are two basic types of die casting machines: Hot-chamber machines and Cold-chamber machines. These are rated by how much clamping force they can apply

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EQUIPMENT Hot-chamber machine

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EQUIPMENT

1. The die is closed and the piston rises, opening the port and allowing molten metal to fill the cylinder.

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EQUIPMENT

The plunger moves down and seals the port pushing the molten metal through the gooseneck and nozzle into the die cavity, where it is held under pressure until it solidifies.

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EQUIPMENT

The die opens and the cores, if any, retract. The casting remains only in the ejector side. The plunger returns, allowing residual molten metal to flow back through the nozzle and gooseneck

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EQUIPMENT

Ejector pins push the casting out of the ejector die. As the plunger uncovers the filling hole, molten metal flows through the inlet to refill the gooseneck, as in step (1).

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EQUIPMENT

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EQUIPMENT

Hot chamber machines are used primarily for zinc, copper, magnesium, lead and other low melting point alloys. The injection mechanism of a hot chamber machine is immersed in the molten metal bath of a metal holding furnace. The furnace is attached to the machine by a metal feed system called a gooseneck. As the injection cylinder plunger rises, a port in the injection cylinder opens, allowing molten metal to fill the cylinder. As the plunger moves downward it seals the port and forces molten metal through the gooseneck and nozzle into the die cavity. After the metal has solidified in the die cavity, the plunger is withdrawn, the die opens and the casting is ejected.

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EQUIPMENT

Cycle in hot-chamber casting: (1)with die closed and plunger withdrawn, molten metal flows into the chamber; (2)Plunger forces metal in chamber to flow into die, maintaining pressure during cooling and solidification; and (3)Plunger is withdrawn, die is opened, and solidified part is ejected. (4)Finished part is shown in (4).

DIE CASTING Cold-Chamber Machine

EQUIPMENT

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EQUIPMENT

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EQUIPMENT

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EQUIPMENT

Cycle in cold-chamber casting: (1)With die closed and ram withdrawn, molten metal is poured into the chamber; (2)Ram forces metal to flow into die, maintaining pressure during the cooling and solidification; and (3)Ram is withdrawn, die is opened, and part is ejected. Used for higher temperature metals eg Aluminum, Copper and alloys

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ADAVANTAGES AND LIMITATIONS

Die casting offers a broader range of shapes. Parts have long service life. High-speed production Closer tolerances Little or no machining is required Thousands of identical castings can be produced before additional tooling is required. Die casting produces parts that are durable They are also heat resistant. Die cast parts are stronger than plastic injection moldings having the same dimensions.

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ADAVANTAGES AND LIMITATIONS

Thin wall castings are stronger and lighter than those possible with other casting methods. Die castings do not consist of separate parts welded or fastened together and the strength is that of the alloy rather than the joining process. Die cast parts can be produced with smooth or textured surfaces They are easily plated or finished with a minimum of surface preparation. Die castings provide integral fastening elements, such as bosses and studs.
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ADAVANTAGES AND LIMITATIONS

Die castings provide integral fastening elements, such as bosses and studs Rapid cooling provides small grain size and good strength to casting Limitations: Generally limited to metals with low metal points Part geometry must allow removal from die cavity

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SELECTION OF ALLOYS

Materials Die casting typically makes use of non-ferrous alloys. The four most common alloys that are die cast are shown below, along with brief descriptions of their properties. (Follow the links to search the material library). Materials Properties Aluminium alloys Low density Good corrosion resistance High thermal and electrical conductivity High dimensional stability Relatively easy to cast Requires use of a cold chamber machine

DIE CASTING Copper alloys

SELECTION OF ALLOYS High strength and toughness High corrosion and wear resistance High dimensional stability Highest cost Low die life due to high melting temperature Requires use of a cold chamber machine Very low density High strength-to-weight ratio Excellent machineability after casting Use of both hot and cold chamber machines

Magnesium alloys

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SELECTION OF ALLOYS

Zinc alloys

High density High ductility Good impact strength Excellent surface smoothness allowing for painting or plating Requires such coating due to susceptibility to corrosion Easiest to cast Can form very thin walls Long die life due to low melting point Use of a hot chamber machine

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DIE CONSTRUCTION

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DIE CONSTRUCTION

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DIE CONSTRUCTION

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DIE CONSTRUCTION

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DIE CONSTRUCTION

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DIE CONSTRUCTION

Tooling The dies into which the molten metal is injected are the custom tooling used in this process. The dies are typically composed of two halves - the cover die, which is mounted onto a stationary platen, and the ejector die, which is mounted onto a movable platen. This design allows the die to open and close along its parting line. Once closed, the two die halves form an internal part cavity which is filled with the molten metal to form the casting. This cavity is formed by two inserts, the cavity insert and the core insert, which are inserted into the cover die and ejector die, respectively.

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DIE CONSTRUCTION

The cover die allows the molten metal to flow from the injection system, through an opening, and into the part cavity. The ejector die includes a support plate and the ejector box, which is mounted onto the platen and inside contains the ejection system. When the clamping unit separates the die halves, the clamping bar pushes the ejector plate forward inside the ejector box which pushes the ejector pins into the molded part, ejecting it from the core insert. Multiple-cavity dies are sometimes used, in which the two die halves form several identical part cavities.

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DIE CONSTRUCTION

Die channels The flow of molten metal into the part cavity requires several channels that are integrated into the die and differs slightly for a hot chamber machine and a cold chamber machine. In a hot chamber machine, the molten metal enters the die through a piece called a sprue bushing (in the cover die) and flows around the sprue spreader (in the ejector die). The sprue refers to this primary channel of molten metal entering the die. In a cold chamber machine, the molten metal enters through an injection sleeve. After entering the die, in either type of machine, the molten metal flows through a series of runners and enters the part cavities through gates, which direct the flow.

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DIE CONSTRUCTION

Often, the cavities will contain extra space called overflow wells, which provide an additional source of molten metal during solidification. When the casting cools, the molten metal will shrink and additional material is needed. Lastly, small channels are included that run from the cavity to the exterior of the die. These channels act as venting holes to allow air to escape the die cavity. The molten metal that flows through all of these channels will solidify attached to the casting and must be separated from the part after it is ejected. One type of channel that does not fill with material is a cooling channel. These channels allow water or oil to flow through the die, adjacent to the cavity, and remove heat from the die.

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PROCESS CYCLE

Process Cycle The process cycle for die casting consists of five main stages, which are explained below. The total cycle time is very short, typically between 2 seconds and 1 minute. Clamping The first step is the preparation and clamping of the two halves of the die. Each die half is first cleaned from the previous injection and then lubricated to facilitate the ejection of the next part. The lubrication time increases with part size, as well as the number of cavities and side-cores.

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PROCESS CYCLE

Also, lubrication may not be required after each cycle, but after 2 or 3 cycles, depending upon the material. After lubrication, the two die halves, which are attached inside the die casting machine, are closed and securely clamped together. Sufficient force must be applied to the die to keep it securely closed while the metal is injected. The time required to close and clamp the die is dependent upon the machine - larger machines (those with greater clamping forces) will require more time. This time can be estimated from the dry cycle time of the machine.

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PROCESS CYCLE

Injection The molten metal, which is maintained at a set temperature in the furnace, is next transferred into a chamber where it can be injected into the die. The method of transferring the molten metal is dependent upon the type of die casting machine, whether a hot chamber or cold chamber machine is being used. The difference in this equipment will be detailed in the next section. Once transferred, the molten metal is injected at high pressures into the die. Typical injection pressure ranges from 1,000 to 20,000 psi. This pressure holds the molten metal in the dies during solidification.

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PROCESS CYCLE

The amount of metal that is injected into the die is referred to as the shot. The injection time is the time required for the molten metal to fill all of the channels and cavities in the die. This time is very short, typically less than 0.1 seconds, in order to prevent early solidification of any one part of the metal. The proper injection time can be determined by the thermodynamic properties of the material, as well as the wall thickness of the casting. A greater wall thickness will require a longer injection time. In the case where a cold chamber die casting machine is being used, the injection time must also include the time to manually ladle the molten metal into the shot chamber

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PROCESS CYCLE

Cooling The molten metal that is injected into the die will begin to cool and solidify once it enters the die cavity. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed. The die can not be opened until the cooling time has elapsed and the casting is solidified. The cooling time can be estimated from several thermodynamic properties of the metal, the maximum wall thickness of the casting, and the complexity of the die. A greater wall thickness will require a longer cooling time. The geometric complexity of the die also requires a longer cooling time because the additional resistance to the flow of heat.

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PROCESS CYCLE

Ejection After the predetermined cooling time has passed, the die halves can be opened and an ejection mechanism can push the casting out of the die cavity. The time to open the die can be estimated from the dry cycle time of the machine and the ejection time is determined by the size of the casting's envelope and should include time for the casting to fall free of the die. The ejection mechanism must apply some force to eject the part because during cooling the part shrinks and adheres to the die. Once the casting is ejected, the die can be clamped shut for the next injection.

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PROCESS CYCLE

Trimming During cooling, the material in the channels of the die will solidify attached to the casting. This excess material, along with any flash that has occurred, must be trimmed from the casting either manually via cutting or sawing, or using a trimming press. The time required to trim the excess material can be estimated from the size of the casting's envelope. The scrap material that results from this trimming is either discarded or can be reused in the die casting process. Recycled material may need to be reconditioned to the proper chemical composition before it can be combined with non-recycled metal and reused in the die casting process.

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RUNNER DESIGN

Runner system with V shape Vertical runner system

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RUNNER DESIGN

Runner system with V shape

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RUNNER DESIGN

Horizontal runner system with V shape

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RUNNER DESIGN

Horizontal runner system with four aligned parts

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RUNNER DESIGN

DIE CASTING Possible Defects Defect Flash Unfilled sections

DEFECTS AND CAUSES

Causes Injection pressure too high Clamp force too low Insufficient shot volume Slow injection Low pouring temperature Injection temperature too high Non-uniform cooling rate

Bubbles

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DEFECTS AND CAUSES

Hot tearing

Non-uniform cooling rate

Ejector marksCooling time too short Ejection force too high Many of the above defects are caused by a non-uniform cooling rate. A variation in the cooling rate can be caused by non-uniform wall thickness or non-uniform die temperature.

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DEFECTS AND CAUSES

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DEFECTS AND CAUSES

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DEFECTS AND CAUSES

cold shut misrun

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DEFECTS AND CAUSES

blow hole

sand and slag inclusions

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