High pressure Die Casting is an ideal process for the manufacture of high volume parts that require high dimensional accuracy and good surface finish with a minimum of machining.
This is a repetitive process which produces high strength and allows for castings to be made with a thinner wall sections than those of the sand or gravity process e.g. 1.5-3mm.
High pressure die castings cannot be heat treated, but they can be treated in order to improve dimensional and metallurgical stability.
Castings may be quenched from the side and machine size will limit casting size. Sound thick sections are difficult to cast and core configurations must be complex to enable dis-assembly.
High pressure castings can suffer from porosity, although evacuated chamber and other techniques may reduce this. High start up costs are only reduced by long casting runs, this delivering low unit cost with high volume production.
High Pressure Die Casting Process
Dyson Diecastings has been developing zinc and aluminum cast components since 1917. Refinements in both the alloys and the process have expanded our applications to most market sectors.
Size, shape, thickness, strength and precision combine to offer designers unsurpassed qualities in performance and visual aesthetics.
The basic die casting process consists of injecting molten metal under high pressure into a steel mold called a die.
Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die. Dyson Diecastings’ machine sizes range from 180/800 tonne. Regardless of their size, the only fundamental difference in die casting machines is the method used to inject molten metal into die.
The two methods are hot chamber or cold chamber. A complete die casting cycle can vary from less than one second for small components weighing less than one ounce, ranging from-two to-three minutes for a casting of several pounds, making die casting the fastest technique for producing precise non-ferrous metal parts.
High pressure die casting is relevant to components that feature/require:
- thin wall
- near net shape
- lower weight
- lower cost
- high definition
- surface finish.