Aluminum is a very important metal in manufacturing, and this is because of its versatile properties and the various applications of both the processed metal and its alloys in different industries.
High pressure die casting enables the quickest route from molten metal to the completed component. This is achieved by injecting molten metal into a hardened tool steel mould, and allowing it to cool and solidify under pressure before it is removed. This process provides a precise, fast cost effective method of production for aluminum or zinc die castings, which meets the needs and requirements of hi-tech industries where the appearance of the product and the the dimensional tolerances are critical and volumes are not always large.
Aluminum is used in the process of aluminum high pressure die casting, and is a metal that has many advantages which is ideal for use in the casting of metal alloys. One of the many reasons that aluminum is is used in the die casting process is the properties of the metal itself. Aluminum has a number of characteristic features which are ideal for this process. Aluminum is very light in weight and and highly ductile and can easily be beaten into different shapes and sizes depending on the needs and requirements. It is also extremely malleable and has very good dimensional stability allowing it to attain complex shapes and thin walled components. Aluminum is dust and corrosion resistant and has good electronic properties and excellent thermal characteristics, and because it is a good conductor of heat it is able to retain the heat and and take good shape in the cast.
Pressure die casting is a competitive casting method when components are needed in high volumes, or when tighter tolerances and better quality surface finishes are required that can be achieved by gravity die casting. Also the need for machining is very low due to the close casting tolerances. Heat treatment of pressure die casting is not possible, but due to the high rate of solidification the mechanical properties are very good, however; the tooling costs are considerably higher than they are for gravity die casting.
Ther are many different die casting alloys and these include: aluminum, zinc, lead, copper, magnesium and tin. Two dies are used for casting; the cover dies half and the ejector dies half, and where they meet is called the 'parting line'. The dies are designed to enable the finished casting to slide off the cover half of the die and remain in the ejector half as the dies are opened.
Other die components include slides and cores. The cores are components that usually produce openings or holes, but they can be used to create other details as well. There are three types of cores, loose, movable and fixed. Loose cores are used to create intricate details and are inserted into the die by hand. Fixed cores are oriented parallel to the pull direction of the dies, and are permanently attached to the die. Movable cores are oriented in any other way than parallel to the pull direction. They are removed from the die cavity after the shot solidifies.