GTTC

DIE CASTING
THEORY
DTDM FINAL YEAR

SHIVAKUMAR K S

GOVT TOOL ROOM & TRAINING CENTRE, HARIHAR

 DIE CASTING
INTRODUCTION:
Pressure die-casting is about 150 years old. The process requires high-
pressure injection of molten metal into a steel die to produce intricate metal
parts, in quick succession.

These parts are mostly ready for end-use, with or without or with minimal
post-casting operation. The process is said to be the shortest distance
between the raw material and the finished components, produced in large
quantities.

The first manually operated die-casting machine got patented in 1849, to

cast “printing type” for type writers. The die-casting technology including die
making and processing have advanced considerably. Various compositions of
tin and lead were the first alloys used for die casting.

Subsequent developments of zinc and aluminum alloys were followed by

magnesium and copper.

Every new job requires original through in its design and the solving of
individual problems in its manufacture. Each die cast component, currently in
production, present a challenge for the improvement of its output and quality.

PROCESS DESCRIPTION

Pressure die casting is a process in which molten metal is forced. Under

high pressure into a cavity metal die in a fraction of a second and then allow
solidify. When the casting has solidified die is open and the die casting is
removed [ejected]. The process is rapid and allows and complex shapes to be
cast as almost finished parts and many thousand of casting can be produced
from the set of die without significant changes in casting dimension.

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CENTRIFUGAL CASTING
Centrifugal casting refers more specifically to the forces used to distribute the
metal in the mould rather than a specific moulding process. However, since
moulds for centrifugal casting are usually specially designed it considered as a
process. Centrifugal casting falls into three categories.

1. True centrifugal casting

2. Semi centrifugal casting
3. Centrifuging

GRAVITY DIE CASTING

The metallic mould generally made in two halves to enable the casting to
be taken out. The inner surfaces of mould are coated first with lamp block or
core oil. the reduces the chilling effect on the cast metal and facilitates easy
removal of the casting. the mould halves are closed and the molten metal
poured into the top in this process the liquid metal flows into the die entirely
under it’s own weight and hence it is known as gravity die casting.

PRESSURE DIE CASTING

Pressure die-casting is a process in which molten metal is forced. Under
high pressure into a cavity metal die in a friction of a second and then allow
solidify. When the casting has solidified die is open and the die-casting is
removed [ejected]. The process is rapid and allows and complex shapes to be

Cast has almost finished parts and many thousands of casting can be
produced from set of die without significant changes in casting dimension.

There are two basic die casting process the hot chamber process. The hot
chamber process is used for die casting metals that melt at lower temperature.
For [low fusion alloys] such as zinc and lead. The cold chamber process is
used for metals that melt at higher temperature. [High fusion alloys] such as
aluminum , magnesium and brass.

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ADVANTAGES OF PRESSURE DIE CASTING

1. More complex shapes can be produced by pressure die casting then gravity
die casting Vi2-carburetor, break drums, breaks holes etc.
2. Since the die are filled under pressure, casting with a thinner wall, greater
length to thickness and greater dimensional accuracy can be obtained.
3. Higher rate of production.
4. Casting are produced as almost finished parts.
5. Thousands of casting can be produced without any significant change in
dimension thus ensuring consistency.
6. May die-casting be able to plated with minimum penetration?
7. Die-casting produces line grain stratum there by having better mechanical
properties.

DISADVANTAGES

1. Casting size is limited.

2. Depending upon the casting profile and gating difficulties may be
encountered viz, Are trapping in the die which may be cause porosity in the
component.
3. Die casting process required costly equipments and hence large quantities
of components are required for the process to be economical.
4. Commercial production is limited to non-ferrous metals only.
5. If casting is of complicated shapes, the contraction operation and
maintenance becomes complicated.

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HOT CHAMBER PROCESS

The basic component of a hot-chamber die-casting machine and die are

illustrated in fig. In the hot chamber process the plunger and cylinder are

submerged in the molten metal in the holding furnace. The power to pump zinc

into the die cavity is provided by a hydraulic accumulator. Oil is applied to the

accumulator by a hydraulic pump at a rate that will bring the accumulator

pressure up to the desired operating level each time a casting [shot ] is to be

made .

The casting sequence in the hot chamber die casting process is illustrated

in fig. When a shot is made, the control valve opens causing the shot cylinder

to force the plunger down and force molten metal through the nozzle past and

spur pin through the runners and gate and into the die cavity. The gases that

were in the system and some of the molten metal flow through the die cavity

and out through vents and / or into over flow. After the cavity is filled the metal

is allowed to solidify the casting is ejected and the cycle is repeated. Since the

gooseneck and plunger are submerged in molten metal the system refills

automatically when the plunger is withdraw.

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COLD CHAMBER PROCESS

The casting sequence for the cold chamber process is illustrated in fig. In
this process molten metal is loaded into the cold chamber and then plunger
advances to force the metal into the die. Except for the manner in which
molten metal is fed into the shot system and injected in to die the casting
sequence for the two processes are similar.

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CLAMP MECHANISM

Because of the tremendous pressure used to inject the molten into the die,
large forces are required to the hold the two die halves together. This holding
forces is accomplish with the tie-bar-platen toggle type machine construction
arrangement not only achieving the required holding [clamping] force but it
also opens and closes the rapidly. Thus speed helps achieve the high
production rates of the die casting process.

DIE CASTING DIES

Die casting dies consists of two parts the cover half and the ejector half,
which meet at the parting line. The basic components of hot chamber die
casting die are illustrated in fig. The cover half of the die is secured to the runt
or stationary platen of the machine, the spur for filling the die cavity is in this
half and it is aligned with the nozzle of the hot chamber machine. The ejector
half of the die is attached to the movable platen of the machine. It contains the
ejection mechanism and in most cases the runners. The die cavity, which
forms the part being cast, is machined into both halves of the die block or into
insert that are installed in the die blocks. The die is designed so that the
casting remains in the ejector half when the die opens. The casting is then
pushed out of the cavity with ejector pins that come through holes in the die
and are actuated by the ejector plates. Which does the machine power. Guide
pins extending from one die half enter holes in the other die half as the closes
to insure alignment between the two halves.

Dies that produce casting with complex shaper may contain stationary and
core pins or hydraulic cylinders movable core. The movable cores and are
locked in place when the die is closed.

Since the casting machine operates at high rates heat must be removed
from the die at a high rate. Heat is removed from the die by circulating water or
other coolant through channels drilled in the die blocks. Heat sometimes is
added to the die by electric or gas heaters for warm up or for making thin
section, which transmit insufficient heat to maintain the die at the proper
operating temperature.

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THE DIE CASTING DIE AND MACHINE RELATIONSHIP:

The die casting machine may be viewed at a pump that has to fill a die
cavity at a given pressure P and in a given time (cavity fill time) the cavity fill
time depends on the flow rate Q. A good die casting die must full fill two basic
requirements.

1. Casting fill time should be less than 20 milliseconds for achieving plating
grade finish and not more than 40 milliseconds for painting grade or
mechanical grade finish.
2. Gate velocity should ideally be in the range of 40 to 50 M/S but never
outside the range 30 to 60 M/S.

The P-Q2 diagrams helps in designing dies to full fill the above
requirements and there by achieve first shot success.

If a hydraulic pump is considered at a given pressure p will be inversely

proportional the square of q (rate of flow) the product p.q2 is a constant typical
p q diagram is shown in fig(m/c line ) from the graph it is clear that as pressure
increases the rate of flow decrease the die-casting machine can be considered
as a hydraulic pump. For water or any liquid flowing through a pipe the
pressure ‘p’ is directly proportional to the of the flow rate ‘q’ higher the
pressure on a fluid flowing through a given pipe higher would be its flow rate
molten zinc and aluminum at their respective holing temp. Behave the
possesses hydraulic constants equivalent to water. A graphical representation
of the relation between ‘p’ and ‘q2’ is shown in fig the slope of this line
depends on the cross sectional area of pipe, corresponding to gate/runner
area.

SHORT WEIGHT

Variation in shot weight can influence the quality of casting by affecting.

1. The volume of gases in the shot sleeve [filling of the shot sleeve]
2. The average metal temperature entering the die.
3. The size of the slug which in turn influences the transmission of force the
plunger to the casting

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4. The position of the metal at the change over from slow to fast injection
5. The start of intensification on machines when it is initiated from a position
switch

In some cases on excessive shot weight can be dangerous

because very long slugs can bursts and injure the operator the as the die
opens.

LOCKING FORCE:

Locking force dependent on the locking pressure tie bar nut setting
and temperature of the die and surroundings. As the dies heats up locking
force increases and unless an allowance has been made this increase the
machine will stall when locking for a giver tie bar nut settings increasing the
pressure to the locking force.

Locking force injection pressure and projected area of the casting

together with die distortion are the factors controlling flash for the best results
the die should where possible the designed so that the centre of pressure
produced in the cavity acts in the centre of the area within the tie bars i.e, the
impression should be positioned centrally with in tie bars.

On some machines the hydraulic pressure control valve for the locking
circuit is situated upstream of the valve controlling the injection pressure with
result that lowering the locking pressure can also lower the injection pressure
little is to be gained by lowering the locking pressure if one wished to reduce
wear in toggle linkages etc when producing small casting the tie bar nuts
should be slackened for this purpose a plot of locking force against the bar nut
positioned is useful.

LUBRICATION :

Correct lubrication of the die and of shot sleeve and plunger is very
important because it affects the soundness and surface finish of the casting
and the life of the shot sleeve and plunger.

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 DIE TEMPERATURE:

No one die temperature can be recommended for producing

acceptable casting because not only does the correct temperature very from
die to die both perpendicular to the surface and across the surface finish is
largely controlled by the die face temperature at injection the casting
dimension are dependent on the temperature of the casting of ejection and to
a lesser temperature can also cause blister in the castings.

Correct die temperature distribution and cooling can increase

soundness by improving the freezing pattern in some cases sounder casting
are produced during the warm-up period then when the die is up to full working
temperature. This is because the extremities of the casting tend to freeze
faster relative to the feed area (the runner/gate area) during the early shots.

Die temperature is governed by the casting rate cooling water flow

and temperature the maximum heat extraction rate is by having the highest
ratio possible of the time when the casting is in contact with the die compared
with the non-contact period i.e, approximately die close time/die open time
should be maximum.

The die is cooled by the cooling water radiation and conduction to

the surrounding machine and atmosphere generally the cooling effect of the
die lubricant is negligible for example in the case of a 2-impression zinc Door
handle casting the following heat input and extraction on figures were recoded
and calculated on the assumption that the lubricant extracted and maximum
amount of heat i.e, the lubricant war turned into dry steam.

Ratio heat extracted by cooling water/heat input from casting =0.84

Ratio heat extracted by die lubricant/heat input from castings=0.06

The die lubricant used was delicate 5:1with water even in cases
where excessive lubricant is used, sometimes with the object of cooling the
die it is surprising how little cooling is achieved by the water / lubricant
because only a thin layer on the die is cooled and then rapidly heated by the
bulk of the sub-surface material.

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 FILLING RATE :Filling rate can be considered in terms of

A) Cavity fill time, unit millisecond

B) Cavity filling rate of volume flow rate during fill unit: m3/s

C) Gate velocity unit : m/s

For a given die all three can be related by simple mathematical

relationship none is the all important from the point of view of die wear and
soldering problem in the gate area.

1. CYCLE TIME [DIE CLOSING TIME]

The time that the die remains closed after cavity filling [die-closed
time dweal time] influences the surface temperature at the next injection by
how much depends on the between shots.

2.TIME BETWEEN SHOTS

This governs the surface cooling takings place before the next injection

DIE SURFACE COOLING RATE BETWEEN SHOTS.

This is governed by

-Heat transfer rate through the die [material and size factors.]

-Heat transfer rate across the die/bolster joint.

-Radiation and convection heat losses from the die surface.

-Internal cooling channels.

-Properties of circulant [coolant]

-Size and location of channels.

-Condition of channel walls.

-Flow rate of circulant [coolant]

-Temperature of circulant.

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COMPARISION OF DIFFERENT DIE CASTING MACHINES

Features Hot chamber Horizontal cold Vertical cold

Machine Chamber machine Chamber machine
Die casting Can handle only Can handle both low Both high and low fusion alloys
alloys L-fusion alloy and high fusion alloy

Furnace Situated with in the machine Out side the machine Out side the machine

Gating Center gating is possible Center gate is not possible Center gate is possible

Cycle time Is lower than other More than hot chamber machine More than hot chamber
machines machine

Loss of heat Is minimum More than hot chamber More than hot chamber
machine

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 CLASSIFICATION OF DIE CASTING MATERIALS

NAME SPECIFIC DENS MELTING SHRIN ADVANTAGE DISADVANTAGE APPLICATION

OF THE ACTION ITY POINT KAGE
ALLOY
Zink Zamak.3 7.13 420’c 0.5% 1.very good cast ability 1.weight is more M/c parts, utensils
alloys and 2. low melting point 2.moderate Toy’s, auto-mobile
zamak.5 3.good m/c ability corrosion and acid Parts, pressure
4.veary good dimensional resistance Tight parts
stability
5.can take very good
surface finish

AL alloy LM2, 2.7 660’c 0.6% 1.Low density 1.Because of it’s Auto mobile parts,
LM4, 2.good strength to weight high melting point Electrical parts,
LM6, ratio die life is less house
LM24 3.good machine ability compared to Zn Hold equipments,
4.good dimension stability alloy General engineering
5.good thermal and parts etc
electrical conductivity
6.can be easily plated and
pointed
7.good cast ability
8.good corrosion
resistance

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Mg alloy MgAlg1, 1.74 650’c 0.7% 1.very low weight 1.highly inflame Portable hand Tool
MgAlg1 1.74 650’c 0.7% 2.good dimension stability able
3.excellent machine ability 2.it need very
4.good cast ability careful storing
5.good surface finish 3.much care has to
be exercised while
melting Mg alloy

Copper 8.5 900’c 0.8-1% 1.very good mechanical 1.very high melting Auto mobile gears
alloy properties point makes die Pumps bearings
2.good thermal and life very less Electrical
electrical property 2.high density and equipments etc
3.good corrosion shrinkage
resistance 3.poor cast ability

Tin 7.3 232’c 0.2- 1.good corrosion and acid 1.poor mechanical Food processing
alloys 0.4% resistance properties industries and
2.good cast ability 2.high density. Bearing etc
3.good surface finish
4.low melting point
Lead 11.35 327’c 0.3- 1.good corrosion and acid 1.poor mechanical Fire extinguishing
alloys 0.5% resistance properties Parts, X-ray
2.resistance to X-ray 2.very high density equipments
3.good dimension stability

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 DEFECTS AND REMEDIES
1. SINK MARK: Shallow smooth depression on the castings surface.
CAUSES REMEDIES
1. Uneven shrinkage Adjustment the die temperature and metal
temperature
2. Sudden change in the casting Avoid sudden change in the casting
section

2. POROSITY: Holes in the casting

CAUSES REMEDIES
1. Low die temperature. Increase dies temperature.
2. Low shot speed. Increase shot speed.

3. Clogged/Insufficient air vent. Clean/provide sufficient air vent.

4 Excessive die release material Reduce die release material.

5. Excessive die locking force. Reduce die-locking force.

3. EXCESSIVE FLASH: Indicates that an extra thick casting is being made and
is potential safety hazard from die splitting
CAUSES REMEDTES
1. Low dies locking force. Increase die locking force.
2. Excessive short speed Decrease short speed.
3. Excessive injection pressure. Reduce injection pressure.

4. Parting line surface un-cleaned. Clean the die surface.

5. Metal temperature. Too high Reduce metal temperature.

6. Worn out tie bars and bushes. Replace worn out tie bars and bushes.

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4. SOLIDERING: This condition is the result of the cast metal bonding to the die
surface.

CAUSES
1. Excessive metal temperature.
2. Incorrect die temperature.
3. Insufficient die release material.
4. Rough die surface.
REMEDIES
Reduce metal temperature.
Maintain correct die temperature.
Increase the die release material.
Polish die cavity.

5. Wrong alloy composition. Use correct alloy composition.

5. CRACKS: Casting may cracks from internal stress or form abnormal pressure
during ejection.
CAUSES REMEDIES

1. Internal stress is created due to Maintain correct die and material

excessive material temperature. Or temperature.
abrupt change of section thickness.

2. Insufficient die release material. Increase the die release material.

3 .Indirect result of soldering. Check for soldering.

4. Insufficient draft taper. Increase draft taper.

6. HEAT MARKS: These are actually shrinkage pits in the casting surface.
CAUSES REMEDIES
1. Excessive metal or die Reduce metal temperature. and Die
temperature. temperature.

2. Depressed areas and sharp Control flow of cooling water.

corners.

3. Clogging of air vent. Cleaning of air vents.

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7. FLOW LINES: Are formed on the external surface of the casting and is very
difficult to remove.
CAUSES REMEDIES
1. Low metal and die temperature. Increase metal and die temperature.

2. Low shot speed. Increase shot speed.

3. Excessive die release material. Reduce die release material.

4. Insufficient air vent. Improve air venting.

5. Improper gating. Change the gate position.

8. BLISTERS: Bubble like bumps on the casting surface.

CAUSES REMEDIES
1.Air or gases trapped inside the Clean air vent/provide air vents.
casting

2. Incorrect shot speed. Reduce shot speed.

3. Excessive die temperature. Reduce die temperature.
4. Excessive die release material. Use less die release material.
5. Excessive die locking force. Reduce die- locking force.
6. Improper gating and runner. Improper gate and runner.

9. BROKEN/BENT PART: A portion of casting may stick in the die during ejection
and the rest of the casting break away and eject normally.
CAUSES REMEDIES
1.Excessive metal or die Reduce metal temperature. or die
temperature. temperature.
2. Insufficient draft tapers. Provide sufficient draft tapers.
3. Too high or low solidification time. Set the die solidification time just right.

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10. LACK OF FILL: The material is not filled completely in the die cavity.
CAUSES REMEDIES
Correct amount of material should be
1. Inadequate material. put in the shot sleeve.

Maintain correct die and metal

2. Cold metal, cold die or both. temperature.

3. Slow shot speed. Increase shot speed.

11. COLD SHUT: This is similar to lack of fill.

CAUSES REMEDIES
1. Cold metal or cold die. Maintain correct die and metal
temperature.

2. Slow shot speed. Increase shot speed.

3. Clogging of air vents. Cleaning of air vents.

12. SEVERE CHILL: This is similar to cold shut, but it will cover a large surface
of the casting instead of being a single line.

CAUSES REMEDIES
1 .Excessive use of die release Reduce die release material.
material.

2. Cold metal or cold dies. Maintain correct die and metal

temperature.

3. Slow shot speed. Increase shot speed.

4. Clogging of air vents. Cleaning of air vent.

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F ADVANTAGES OF DIE CASTING

01. Die casting provides complex shapes within closer tolerance than many
others mass productions processes.

02. Die casting are produced at a high rate of production little or no machining is
required.

03. Die-casting can be produced with thinner walls then those obtained by other
castings method and much stronger then plastic injection moldings with the
same dimension.

04. Die casting provides parts, which are durable, dimensionally stable, and have
the feel and appearance of quality.

05. Die casting dies can produce thousands of identical casting with in specified
tolerances before additional tooling may be required

06. Zinc casting can be easily plated or finished with a minimum of surface
preparation

07. die- casting can be produced with a surface simulating a wide variety of
textures.

08. Die cast surface, as cast are smoother than most other form of casting.

09. Holes in die casting can be readily die cast.

10. External threads on cans can be readily die cast.

11. Die casting provides integral fastening elements, such as bosses and studs,
Which can result in assembly economies.

12. Inserts of other metals and some non –metals can be die cast in place.

13. Corrosion resistance of die casting alloys rates from good to high.

14. Die-casting combines many functions in one, complex shaped part. Because
die casing do not consist of separate parts, welded or fastened together, the
strength is that of the material, not that of threads or welds, etc

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 F GUIDES FOR DESIGN

Advice on designing die- casting is usually based upon desirable practices

or situations to avoid. However like most rules there are exceptions. These
affects their cost appearance and or quality of final products listed below or
guides which should be considered when designing for die – casting.

01. Specify thin sections, which can easily be die- cast and still provide
adequate strength and stiffness use ribs wherever possible to attain
maximum strength minimum weight.

02. Keep section as uniform as possible. Where section must be varied make
transitions gradual to avoid non-essential projections.

03. Keep shapes simple and avoid non-essential projects.

04. A slight crown is more desirable then a large flat surface especially on
pleated or highly finished parts.

05. Specify coring for holes or recesses where savings in metal and overall
costs outweigh tooling costs.

06. Design cores for easy withdrawal to avoid complicated die construction and
operation

07. Avoid smell cores. They can be easily bent or broken necessitating frequent
replacement drilling or piercing small holes in die-casting is often cheaper
than the cost of maintaining small cross

08. Avoid use of under cuts which increases die or operating costs unless
savings in metal or other advantages fully warrant these extra costs

09. Provide sufficient draft on sidewalls and cores to permit easy removal of the
die casting from the die without distortion

10. Provide filets at all inside corners and avoid sharp outside corners deviations
from practice may be warranted by special consideration

11. die casting design must provide for location of ejector pin take in to
consideration the effect of resultant ejector marks on appearance and
function the location of ejector pins is largely determined by the location and
magnitude of metal shrinkage on die part as metal cools in the die

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12. Specify die cast threads overcuts threads when a net savings will result.

13. Die castings which affect the appearance of a finished product, may be
design for aesthetics with mating parts.

14. Inserts should be designed to be held firmly in place with proper anchorage
provided to return then in the die casting

15. Design parts to minimize flash removal costs

16. Never specify dimensional tolerances closer then essential this increases
costs.

17. Designs die castings to minimize machining

18. Where machining is specified allow sufficient metal for required cuts

19. Consider contact area for surface which are to be polished or buffed avoid
deep recesses and sharp edges

Dies can be produced for simple and complex parts having a external
undercuts or projections on side walls after required slides which increases costs
in many cases however resultant saving of metals or other advantages such as
uniform wall sections off set extra costs or effect net economy in overall costs
this is especially true when large quantities or involved.

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