As you would probably know, the metal shaping process of die casting enables foundries to produce mass volumes of engineered metals parts with desired shapes and properties with ease. Die casters use a number of machines and equipment to create metal parts with superior characteristics. In fact, different machines are often used by die casting companies when they are working with different alloys and metals.
The metal manufacturing technique of die casting usually subject the molten metal or die into high-pressure conditions in order to force the die into mold cavities. The metal is then left undisturbed to cool down and to get hardened. Once the die occupies its final shape and form, die casting companies perform a number of surface finishing tasks on the die to improve its properties. Die casters from most professional companies use copper, tin, lead, aluminum, zinc, and other non-ferrous metals in order to fabricate the die cast parts.
It is true that the tooling and machining cost to run die casting operations can be quite expensive. However, the reduced downtime between the manufacturing runs and the ability of the process to produce high volumes of metals within a short span of time makes die casting a popular choice of businesses. Some of the best die casting machines that enable die casting companies to produce uniform and highly durable parts are as follows.
Hot-Chamber Die Casting Machines
There are two types of die casting machines: cold-chamber and hot-chamber die casting machines. Hot-chamber machines are often called as gooseneck machines because of the unique shape of their metal feeding system. These machines contain a pressure chamber, which is directly connected to their mold cavity. This in turn allows the molten metal to flow continuously into the mold cavity.
When the cylinder of the pressure chamber reverts to an unpressurized position, the molten die or metal is fed to the casting die. Die casting processes that use hot-chamber machines are incredibly faster when compared to the processes that use cold-chamber machines.
Cold-Chamber Die Casting Machines
Die casting companies often use cold-chamber die casting machines to shape metals and dies into desired shapes. However, the major issue with these die casting machines is that the molten metal should be automatically ladled or hand-ladled into the machine’s chamber. After that, a hydraulically operated plunger is used to seal off the pressure compartment and force the molten metal into the die.
Die casting companies prefer to use cold-chamber die casting machines because they considerably reduce the amount of heat and minimize the chances of corrosion in the machine’s plunger and associated components. This in turn boosts the productivity of the metal die casting process and helps die casters to reduce the imperfections in the finished product.
Choosing Between Hot-Chamber and Cold-Chamber Die Casting Machines
Die Casting Machines
The major downfall of hot-chamber machines is that they are relatively more prone to corrosion. This is the major reason why hot-chamber die casting machines are used for alloys and metals with reasonable fluidity and low melting temperatures. Some of the most common metals that are used for the process of hot-chamber die casting are magnesium, zinc, lead, and copper.
Since cold-chamber die casting machines are less susceptible to corrosion, these machines are generally used to cast metals and alloys with high melting points. Die casting machines usually use cold-chamber machines when they are working with alloys with high aluminum content and aluminum.
Other Die Casting Machines
Another interesting thing to note is that cold-chamber and hot-chamber die casting machines can be further divided into different subcategories such as squeeze casting machines and semi-solid molding machines. The former set of machines creates heat-treatable and low porosity components that can reduce turbulence and gas entrapment. On the other hand, semi-solid molding machines produce semi-solid metal billets that are suitable for heat-treatable and low porosity operations.
Even though most of the modern die casting machines comes with automation capabilities, die casting companies often use expensive and advanced machines. This is because these machines are capable of automating each and every step in the die casting process including quenching, trimming, ladling, cold-chamber casting, die lubrication, and more. Some of these automated die casting machines also considerably lower the need of manual quality control by coupling the machine with a processing device. These devices adjust and analyze die casting processes based on metal velocity or hydraulic pressure.
Die Cast Types
One of the most crucial components of die casting machines is die casts. Die casting companies commonly use four different types of die casts and they are combination die, unit die, multiple-cavity die, and single-cavity die. Single cavity die is suitable for creating unibody solid components while multiple-cavity die produces large volumes of identical components at a rapid pace. On the other hand, unit die is used for casing different components simultaneously whereas combination die can cast several unique parts for future assembly.