PSG COLLEGE OF TECHNOLOGY
DEPARTMENT OF METALLURGY
DIE CASTING
PROFESSIONAL SKILLS
15Y215
NAME: MUKESHKUMAR MK
ROLL NO: 18Y117
CASTING PROCESS
Billet
A small metal bar
Static metal pressure
The metal pressure in the die cavity at the instant that
the cavity is full
Thixotropy
The property of a fluid mixture to become more fluid as
the mixture is agitated
3-2
Two Major Processes
Hot chamber and cold chamber die casting
Get name from temperature of metal pump relative to
temperature of the metal
In hot chamber, the metal pump is submerged in the metal
and is same temperature as the metal
In cold chamber, the metal pump is outside the furnace
and is cold relative to the metal ladled into it
3-3
Hot Chamber Components
A Frame
Suspends shot
components above
and in the furnace;
mounted to
stationary platen
Shot cylinder
Actuates vertically;
metal is injected
with downward
stroke of the
shot cylinder
3-4
Hot Chamber Components
Coupling
Connects shot
cylinder to plunger
rod and tip
Plunger rod and tip
Pumps the metal;
piston tip has 2
or 3 grooves in it
for piston rings
3-5
Hot Chamber Components
Rings
Prevents metal from
bypassing tip; helps
maintain metal
pressure after die
cavity is filled
Gooseneck
Combination sleeve
and metal path out
of the metal pump
3-6
Hot Chamber Components
Nozzle
Tube connecting
gooseneck to die cast
die; extends from
gooseneck, through
stationary platen, to die
cast die; it’s heated to
keep the metal liquid
in the nozzle
Sprue bushing
What the nozzle seats
against; cooled to assure the metal in it freezes
3-7
Hot Chamber Machine Cycle
3-8
Hot Chamber Process Uses
For low melting point alloys and alloys with a small
aluminum constituent
These alloys include those made from:
Lead
Tin
The Zamak family of zinc alloys, ZA8 zinc alloy and a small
amount of AZ91D magnesium alloy
3-9
Cold Chamber Components
C-frame
Structural framework
that supports the shot
components; mounted
to stationary platen
Shot cylinder
Mounted to the
C-Frame; injects
metal with its
horizontal stroke
3-10
Cold Chamber Components
Coupling
Connects the shot
cylinder to the plunger
rod and tip
Cold chamber
Shot sleeve or tube
that the plunger slides
in to pump the metal
3-11
Cold Chamber Components
Plunger rod and tip
Pumps the metal;
made from highly
conductive material
and is water-cooled
Conventional cold
chamber plunger tips
do not have rings;
newest technology indicates that
the tip may benefit from a design with
rings
3-12
Cold Chamber Machine Cycle
3-14
Cold Chamber Process Uses
Used for high melting point alloys and alloys with a
significant aluminum constituent:
Aluminum
Copper
Magnesium
Iron
Titanium
Composite materials
3-14
Hot Chamber Advantages
Metal temperature control is better maintained
Metal transfer not required
Cooling of piston tip and sleeve not required
Fewer oxidation losses
3-15
Process
Limitations/Variations
Conventional process limited by internal porosity
Due to trapped gases or solidification shrinkage
New technologies developed to provide denser castings
Use vacuum, squeeze casting, or semi-solid and
thixotropic melting/casting methods
3-16
Vacuum Process
Die cavity evacuated using a vacuum pump
Several commercially available systems
Limitations to how complete a vacuum can be achieved;
26-27 inches of mercury seems adequate for most
applications
3-17
Squeeze Casting
Gate velocity is much lower
Gate thickness is much higher
Metal pressures at the end of cavity filling are much
higher
3-18
Semi-Solid Casting
Alloy cast is part liquid and part solid
Premise: defects form during solidification; solids therefore should be free
of defects
Billet of material is preheated to casting temp. in a specially
constructed induction heater
Billet placed in cold chamber, then injected
Uses low gate velocities and high metal pressures to make very dense
castings
3-19
Thixotropic Casting
Takes advantage of the thixotropy
of alloy
When injected and forced through the
gate, literally sheared and agitated, it
flows like a plastic material
Injection system is a combination of
the screw used in plastic injection
and the plunger used in
conventional die casting
3-20
Summary
Two major processes
Components are similar
Process used is based on alloy’s melting point
Hot chamber process has several advantages
Process variations are based on new technologies
Try to overcome conventional die casting’s limitation of
internal porosity
3-21
