Pressure die casting

Pressure die casting is a manufacturing method suitable for producing substantial numbers of small and large parts in series. Other than in investment casting, a permanent mold is used for die casting which is not consumed in the production process. However, the production of the mold is considerably more elaborate. For the die casting process, the liquid metal is injected at high pressure into the casting mold, where it then solidifies.

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How does the pressure die casting work?

For pressure die casting a previously prepared mold or casting die, which usually consists of two or more parts, is heated at high temperatures of up to 300 degrees Celsius. Then the liquid metal is filled into the pre-heated permanent mold at high velocity (up to 12 meters per second) and under high pressure (up to 200 megapascal). Once the mold starts to cool down, the liquid metal solidifies.

The mold survives the process and can be used over and over again, resulting in identical construction parts, which can be produced in very large quantities. A drawback to the pressure die casting method is that it requires the manufacturing of a permanent mold. Since this is more complex than for other production processes, pressure die casting is better suited for high-volume applications to amortize the development cost.

What are the advantages of pressure die casting?

The major advantage of this pressure die casting is the capability to mass-produce large quantities of identical parts. However, there are many other reasons, which also speak for this method, including:

  • Representation of complex geometries.
  • Great precision.
  • Minimal subsequent processing.
  • Production of thin-walled components for weight optimization possible.
  • High stability due to high pressure.
  • Smooth surfaces, high surface quality.
  • Parts can be cast from iron.
  • Cost-effective process for the production of prototypes in the original process.
  • Low initial costs.
  • Short production cycles.
  • High-quantity performance.

Which materials can be used to manufacture pressure die casting products?

The following materials can be used for pressure die casting:

  • Aluminium.
  • Zinc.
  • Magnesium.
  • Silicon tombac.

The most important information at a glance.

Materials: Aluminium , Zinc.
Component: 0.002–10 kg.
weights:
Dimensions:
Tolerances: According to BDG directive,VDG code of practice P690 D1-D3.
Quantities: Medium-sized to large batches.