High Pressure Die Casting

Here, the liquid metal is injected with high speed and high pressure into the
metal mold. The basic equipment consists of two vertical platens. The bolsters
are placed on these platens and this holds the die halves. Out of the two platens,
one is fixed and the other movable.
Steps of Die Casting Process
Whether hot or cold chamber die casting, the standard process involves injecting molten
metal into a die mold under high pressure. Below are the intricate die casting process steps:

· Clamping
The first step in die casting is clamping. However, before then, clean the die to remove any
impurities and lubricate the die for better injection and removal of the solidified product.
After cleaning and lubrication, clamp and close the die with high pressure.

· Injection
Melt the metal you want to inject and pour it into the shot chamber. The procedure
depends on the process you are using. For example, the shot chamber is cold in the cold
chamber die casting, while it is hot in the hot chamber die casting. After that, inject the
metal into the die under high pressure generated by a hydraulic system.
 Cooling
While clamped, allow the metal to cool for solidification. The solidified material will
have a shape similar to the design of the mold.

· Ejection
After unclamping the die mold, an ejection mechanism will push the solid casting out
of the die. Ensure proper solidification before ejecting the final product.

· Trimming
This is the final step, and it involves the removal of the excess metal in the sprue and
runner found on the finished product. Trimming is achievable using a trim die, saw, or
other procedures. The removed metal parts are recyclable and reusable in the
process.
This helps the die to open and close.

A specific amount of metal is poured into the shot sleeve and afterwards
introduced into the mold cavity.

This is done using a hydraulically-driven piston.

After the metal has solidified, the die is opened and the casting eventually
removed.
Types of High Pressure Die Casting:

1. Hot Chamber High Pressure Die Casting

2. Cold Chamber High Pressure Die Casting

Both the processes are described below. The only difference between the two
processes is the method being used to inject molten metal into the die.
One half of the die is attached to a fixed machine plate and the other to a movable one
on a die-casting machine that is horizontally aligned. Because of the high pressure used
when pouring – up to 1,200 bar i.e. 1.2 Mpa – the bolts holding the two halves of the die
together must have a high locking force. As these have a relatively high melting point,
cold-chamber die casting machines are mainly used for aluminium alloys. Here, the
casting assembly is located outside the melt. The molten metal is fed to a shot chamber,
from where a piston drives the metal into the die. Once the metal has cooled and
solidified, the two halves of the die are opened and the casting is automatically ejected
from the die by ejector pins.
Most die castings are made from non-ferrous metals, specifically zinc,
copper, aluminium, magnesium, lead, and tin-based alloys. Depending
on the type of metal being cast, a hot- or cold-chamber machine is used.
What Are the Differences and Similarities between Hot and Cold Chamber Casting?
Hot and cold chamber casting has both similarities and differences in the
process.

The main differences between the two methods are:

•The metal melts inside the pot of the furnace of the machine in the hot chamber. But in
the cold chamber, the metal melts in a furnace separate from the machine.
•There is no need for any ladle in the hot chamber casting process. But in order to put the
liquid metal in the shot chamber, a ladle is necessary for cold chamber casting.
•The liquid metal goes into the cavity via the gooseneck in the hot chamber process. But
the liquid metal goes through the shot chamber in the cold chamber method.
•The overall parts’ production time cycle is less in the hot chamber process than in the cold
chamber.
•The hot chamber process doesn’t allow the cast of metal alloys that have high melting
points. But the cold chamber method allows it.
The similarities between the two casting processes are as follows:
•There are some similar components in both processes. For example, both machines have
one fixed and one movable die.
•An external force is necessary for both processes to push the molten metal into the
cavity.
 Differences between hot chamber and cold chamber die casting are mentioned below.

Hot chamber die casting Cold chamber die casting

1). In hot chamber die casting, the source of molten metal 1). In cold chamber die casting, the molten metal is
is attached to the machine. introduced to the shot chamber from the external source.

2). This process is not suitable for metals which have high 2). The die casting machinery remains cooler as the molten
melting temperatures. metal is applied from the outside source.

3). Alloys having lower melting point can be casted using a 3). Alloys having higher melting point can be casted using a
hot chamber die casting process. cold chamber die casting process.

4). The production rate is higher as the material brought in 4). The material is needed to fill in the cylinder in every
every cycle is constantly outputted. cycle for the production, so the rate of productivity is less.

5). Less pressure is required to apply in the hot chamber 5). Cold chamber die casting process requires high
die casting process.  pressure to be applied on the molten metal.

6). The machinery life is less because the entire cylindrical 6). Machinery life is more as the part of the cylinder and
and plunger are submerged in the molten metal. piston are in contact with the molten metal.
Hot Chamber Die Casting
Hot Chamber Process

The hot-chamber process is applicable only for zinc and other low melting point
alloys that does not affect and erode metal pots cylinders and plungers.

The basic components of a hot-chamber diecasting machine and die are illustrated
below:
1. Die
2. Gooseneck
3. Molten
Metal
4. Plunger
5. Ejector pin
The workings of a hot chamber process goes like this. The molten metal for casting is
placed in the holding furnace at the required temperature adjacent to (sometimes as
part of the machine itself) the machine.

The injection mechanism is placed within the holding furnace and most of its part is in
constant touch with the molten metal.

When pressure is transmitted by the injection piston, the metal is forced through the
gooseneck into the die. On the return stroke, the metal is drawn towards the
gooseneck for the next shot.

This process ensures minimum contact between air and the metal to be injected. The
tendency for entrainment of air in the metal during injection is also minimized.
Hot chamber die casting can be used with zinc, magnesium, and other low
melting alloys .
Parts manufactured using this process include tools, machine components,
carburetors, motors, various housings and toys.
Hot chamber die casting Products
Magnesium Hot chamber die casting Products
What Are the Benefits of Hot Chamber Die Casting?
 
Hot chamber process has a lot of benefits. But its only drawback is that die casting alloys that
have high melting points are not compatible with this method. However, the benefits of this
process are:
Faster Production Cycle
In this casting process, the metal melts inside the pot of the machine furnace rather than
melting in a pot that is detached from the machine. This reduces the delivery time of the
liquid metal from the cylinder to the cavity. For this reason, the production cycle speeds up.
Less Waste and Defects
This process produces minimal waste as in this casting process because of the liquid metal’s
quick transfer. This process also reduces the chance of having defects such as blisters and
porosity in the final part.
Longer Die Life
Manufacturers use metal alloys with a low melting point in this casting method and so the
dies and other components of the machine achieve a longer life.
Disadvantages of Hot Chamber Die-Casting

There are some downsides to using hot chamber die-casting as well.

First, it is only used successfully for casting low-melting metals such as tin alloys, zinc
alloys, and magnesium alloys. If your product requires a metal type that doesn’t lend itself
well to high temperatures, you’ll need to opt for cold chamber die-casting instead.

Hot chamber die-casting requires a high-pressure range that isn’t always suitable for
making every product. It also offers limited metal fluidity due to variance in alloy
malleability, limiting the final product’s shape and/or complexity.

Another disadvantage of hot chamber die-casting is that it’s only cost-effective if you have
a high volume of products that need to be produced. If you only need a limited number of
products, hot chamber die-casting may not be the most cost-efficient option for your
business.
In the case of hot chamber die casting, the biggest drawback is porosity. The die
casting will lead to the formation of bubbles on the metal’s surface if it is fully
treated. Since it cannot be fully treated, there are pores present on the surface,
which can lead to air pockets, weakening the metal in extreme cases. 
Why Aluminum Alloys Are Not Suitable for Hot Chamber Die Casting?
 
Aluminum alloys have a higher melting point than certain casting metals such as zinc or
lead. For this reason, the furnace of the machine of the hot chamber method cannot
withstand the heat to melt aluminum alloys.

If aluminum die-casting was done by hot chamber casting, it would damage the furnace or
the pot where the metal melts. It would also damage other components of the machine, for
example, the gooseneck, the nozzle, the cylinder, etc.

This is why manufacturers produce aluminum alloy parts using the cold chamber method
rather than the hot chamber. Here, manufacturers melt aluminum alloys in a separate
furnace and then pour them into the shot chamber using a ladle.
Hot Chamber Die Casting Video
 
Cold Chamber High Pressure Die Casting
Cold Chamber Process

The difference of this process with the hot-chamber process is that the injection
system is not submerged in molten metal.

On the contrary, metal gets transferred by ladle, manually or automatically, to the shot
sleeve. The metal is pushed into the die by a hydraulically operated plunger.

This process minimises the contact time between the injector components and the
molten metal. Which extends the life of the components.

However the entrainment of air into the metal generally associated with high-speed
injection can cause gas porosity in the castings. In the cold chamber machine,
injection pressures over 10,000 psi or 70,000 Kpa (70 N/mm2) is obtainable.

Generally steel castings along with aluminium and copper based alloys are produced
by this method.
Advantages of Cold Chamber Die Casting
1. Long-lasting and robust components
Cold chamber die casting helps to create parts that are strong and long-lasting. The components
manufactured out of this process are robust and lighter than those possible with other casting
methods and improve the visual appeal of the surrounding area. Plus, because die castings do
not consist of separate parts welded or fastened together, the strength is that of the alloy rather
than the joining process.
2. Cost-effective process
This process is highly effective and saves many costs, helping to create a broad range of
components compared to other manufacturing methods.
3. Increased strength
Cold chamber die casting helps to create stronger parts than those made out of plastic injection
moldings having the exact dimensions.
4. Easy to assemble
This process helps to create fastening elements such as studs and bosses. Holes can be carved,
and external threads can be cast.
5. Accurate in dimension and stability
Using this process, machine parts can be created: heat resistant, dimensionally stable, and
having a high level of tolerance.
6. Better finished products
The process of cold chamber die casting helps to produce smooth parts having a high level of
finish. The products can easily be plated and finished by menial effort.
Disadvantages:
First, the production cycle for this process is a bit longer compared to hot chamber die-
casting. This is because the molten material in the separate chamber may cool down
before the injection takes place. It also requires an additional step compared to hot
chamber die-casting.
Another disadvantage is a high level of oxidation and other contaminants in cold-chamber
die-casting. The molten material is exposed to these contaminants during the process,
impacting the quality of the product.
Die are expensive
Takes more time and space as more manual operations are involved.
Only the products for which wall thickness is lower than 8 mm can be cast.
In both pure metals and many alloys that cannot be heat treated, annealing is used to
remove the hardness caused by cold working.
Parts or components manufactured are easily subjected to shrinkage or porosity from
inside.
An engine block with aluminum and magnesium die castings
Centrifugal casting
What is Centrifugal Casting?

Centrifugal casting refers to several casting techniques which use centrifugal forces
induced by the rotation to distribute the molten metal to the outer regions of a
circular mould cavity, where it solidifies to create a part.

This technology first emerged in the early 1800s, and compared to forgings and
fabrications, can be a cost-effective method of creating complicated near net shape
parts.

Centrifugal casting types

True centrifugal casting, semi centrifugal casting, and centrifuging are the three
forms of centrifugal casting. The process is further divided into, Vertical and
Horizontal, depending on their construction.
How does centrifugal casting work?

Like any other metal casting process, all three of the centrifugal casting process
follow the main casting steps of patternmaking, mould
making, metal melting, molten metal pouring and post-processing.
A family of casting processes in which the molten metal is pouring into mold which is
rotated at high speed (200 - 1000 rpm is reasonable), so centrifugal force distributes
molten metal to outer regions of the die cavity.
The group includes:
 True centrifugal casting.
 Semi-centrifugal casting.
 Centrifuge casting.
The centrifugal casting process marginally differs between the three types but can be
generalised into the following steps.
• The mould wall is coated with a refractory ceramic coating. In the case of True
centrifugal casting mould, it involves applying ceramic slurry while spinning, drying
and then baking.
• Molten metal from an external source is directly poured into the mould without any
gating system through a spout.
• The molten material for the casting can be poured into a rotating mould or the mould
can be rotated after it has been poured.
• The rotating mould’s centrifugal forces drive the molten material to the cavity’s
outside wall once it’s inside.
• Once the desired amount of molten metal is poured, the mould continuously spins
until the part is entirely hardened.
• The mould is removed and opened after the casting has solidified and the casting is
removed.
When to Choose Centrifugal Casting

•Symmetrical parts that can rotate on an axis.

•Static casting material properties are insufficient.
What’s Static Casting?
Static casting is the process of introducing molten metal into a reusable mold to produce
solid, one-piece shapes. The mold consists of two or more sections and has an opening.
Inside the mold are chambers with the desired product shape or features.
Molten metal is poured into the mold. As the melt cools and solidifies, the mold halves are
separated and the finished part is removed.
•Centerline shrink is an issue using other casting processes.
•Limited Interna Diameter features.
•Large parts, up to 135,000 lbs. / 61,350 kg or more.
•High machining costs for Outside Diameter shaping.
•When required alloy will not work or is not feasible for other processes.
•A uniform grain structure is required.
•Dimensional reliability is required.
 Centrifugal casting applications

Centrifugal casting has a wide range of applications in the industry and is used to
make parts such as bushings, engine cylinder liners, rings, brake drums, water supply
lines, sewage pipes, street lamp posts and gas pipes.

They are used in high-reliability applications such as jet engine compressor cases,
hydro wear rings, and numerous military items because they produce components
with excellent material soundness due to very high centrifugal forces.

Typical materials that can be centrifugal cast are metals, cements, concretes, glass,
and pottery materials. Typical metals cast are iron, steel, stainless steels, and alloys of
nickel, aluminum, and copper.
Advantages
• These castings have a high density, a high mechanical strength, an excellent outer
surface finish, and a fine-grained structure.
• Impurities and inclusions can be easily removed
• Gates are risers not required
• Hollow interiors without cores are formed.
• Can form very large parts with high accuracy
• Low equipment and labour cost
• Generates minimum scrap
Disadvantages

• The casting inner surface diameter will not be accurate.

• This method is not suitable for all alloys.
• The true centrifugal casting process is limited to cylindrical parts
• Secondary machining is often required for inner diameter
• Long lead time possible
Centrifugal Casting Bushing
Cylinder Liners
WHY CENTRIFUGALY CASTED PIPES?

Longer Life
The products manufactured by centrifugal casting or spin casting have a longer life
because of its dense and close-grained structure. This characteristic makes the products
withstand higher stress even in the harsh environment. This also saves the users money
because of the low maintenance cost.
Zero rejects
The impurities with low densities would be driven to the inner surface by the
centrifugal force. The impurities and trapped oxides are easily machined off. Therefore,
there is zero rejects by centrifugal casting.
Flexibility of alloy choices
Various materials are able to be casted by centrifugal casting. Thus, it is suitable for
producing custom symmetric components.
 Centrifugal Casting Eliminates Mid-wall Defects
1. The centrifugal process does not rely on discrete risers or feed points to ensure
the absence of trapped porosity. Rather, the inner diameter remains fully liquid
during the solidification process, resulting in a continuous supply of metal to
feed areas of contraction.
2. Unlike conventional gravity or static castings that chill from both the inside and
outside surfaces and risk trapping mid-wall shrinkage, centrifugal castings
solidify from the outside surface inward. The result is a part consistently free of
shrinkage cavities, gas pockets, and blowholes.
Centrifugal Casting Controls Impurities
1. Unique to the centrifugal process is the high force that effectively isolates less
dense substances in the casting’s bore area. These impurities are later machined
away, leaving a defect free part. Molten metal is fed into a rotating mold where a
centrifugal force of up to 100Gs is applied to the metal. Centrifugal force is critical
for this process. The Gs produced are dependent on the RPM and diameter of the
chill mould.
2. The centrifugal force pushes high density metal against the mould sidewall while
lower density components migrate or "float" toward the I.D. These lower density
items include metal oxides, sulfides, gases, and other impurities that would
otherwise have been inclusions in the casting. This phenomenon is termed
“secondary refining".
Centrifugal Casting Greatly Reduces Micro Porosity
1.The combination of directional solidification, impurity migration to the I.D., and
solidification under pressure produces a component with superior defect
distribution
2. and soundness compared to other manufacturing processes.

PRODUCTION LIMITS:-

DIAMETER LENGTH THICKNESS

120-1500 MM UPTO 4500 MM 16-100 MM
Centrifugal Casting Videos