What is die casting? Essentially, die casting uses steel molds called dies which molten metal is forced into using extremely high pressure. From steel sinks to tiny toy cars, die casting is a versatile technique that allows for various levels of complexity in production, while still maintaining absolute precision to create a flawless end product.
The Four Steps of Die Casting
There are four key steps in the process of die casting, and each must be fully completed before moving onto the next phase. However, before these steps can begin, the die worker must ensure that the die casting machine is at the required temperature. If the die is still cold when the molten metal is injected, it will solidify too quickly without conforming to the correct shape. According to the size of the intended cast, heating can take anywhere from several hours to several minutes. After the die has reached the right temperature for the job, casting can begin.
1) Spray the mold with lubricant and close it. This helps to regulate the temperature inside of the die, while also allowing for an easier removal of the cast object later on. The lubricant functions much in the same way as household cooking spray is used on a baking pan.
2) Inject the molten metal into the die. The metal is inserted at an extremely high pressure, which allows the metal to conform to the precise shape of the die, without the dangers of lumps or air pockets inside the product.
3) Cool the mold, and wait for the metal to solidify. In some cases, the mold may be immersed or sprayed with cold water to help the casting become solid faster than simply waiting for it. A high pressure is maintained inside the mold, which ensures the metal doesn’t change properties while inside the die.
4) Open the die and remove the solid cast!
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