The Die Cast Process
The die cast process is similar to injection mold during the process. Die casting is a metal casting process in which molten metal is forced under high pressure into a mold cavity. The mold cavity is simply two hardened tool steel dies which have been machined into a desired shape. Most die castings are made from non-ferrous metals. Hot chamber die casting is used on metals that require high temperature to become molten metal. Cold chamber can be used on low temperature metals.
Die casting equipment represent a large capital investment. Due to the high cost, the die cast process of is mainly used in high volume production. The die cast process includes four basic steps: die preparation, filling, ejection, and shakeout. First, the die is prepared by spraying the mold cavity with lubricant. The lubricant helps control the temperature of the die. In addition, the lubricant will allow the cast to be removed easier. In the filling process, the dies are closed and molten metal is forced into the dies under extremely high pressure. As the dies cool, the cast will become solid. The cast is then ejected. During the shakeout phase, a trim press is used to clean the cast by removing the gate, runners, sprues, and flash from the shot.