Hardware Fitting -High Pressure Die Casting Process - Buick Encore Forums - EncoreOwners.com
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post #1 of 130 (permalink) Old 07-22-2020, 04:50 AM Thread Starter
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Hardware Fitting -High Pressure Die Casting Process

High pressure die casting, also known as traditional die casting, is a metal casting process that involves injecting molten metal (steel, zinc, copper, aluminum, lead, magnesium, etc.) into a three-dimensional mold. Heat the base metal until it reaches a liquid molten state. It is then pressed into the cavity of the mold so that it will assume the shape of the mold once it has cooled.

High pressure die casting is used to manufacture everything from engine blocks to aerospace components and even heavy fasteners. Although the implementation methods are different, most high pressure die casting processes include the following four steps.

#1) Prepare the mold
The first step in high pressure die casting is mold preparation. In this initial step, the manufacturing company applies lubricant to the inner wall of the mold. This is important because the lubricant can regulate the temperature of the mold while also forming a thin film between the molten metal and the mold, making the casting easier to remove.

#2) Injection
After preparing the mold, the manufacturing company injects molten metal into it. In this step, the mold must be closed and sealed. Otherwise, it will not be able to "accept" high-pressure molten metal. Depending on the specific application, molten metal can be injected into the mold at a pressure between 1,500 and 25,000 pounds per square inch. The mold maintains this pressure until the molten metal cools and solidifies.

#3) Cavity pops up
Next, the manufacturing company ejects the newly created cavity from the mold. The mold itself usually has a thimble, which releases the cavity when it is engaged. Of course, the cavity must be strong to eject. If the raw metal is still liquid, the manufacturing company must wait for it to cool before ejecting the cavity from the mold.

#4) Knockout
The fourth and final step of high pressure die casting is shaking. In this step, the manufacturing company will separate all scrap metal from the newly created cavity. It is not uncommon for high-pressure die casting to produce excessive amounts of scrap metal. In other words, not all molten metal is used for casting. Some residue is stuck in the mold. Therefore, scrap metal must be removed before the mold can be reused.

In a nutshell, high pressure die casting usually includes four steps: preparing the mold, injecting molten metal into the mold, ejecting the newly created cavity from the mold, and separating the scrap metal from the cavity.



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