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Pressure Die Casting

Pressure die casting is a casting process that forces molten metal, under extremely high pressure, into a mold. The die will most likely be created from any one of 7, iron free, alloys and metals. They are zinc, aluminum, magnesium, copper, lead, tin and pewter. The reason why metal containing little to no iron us used is due to the high oxidation level of Iron (basically, it will rust easily).

The chamber where the molten metal will be pressed into is either hot or cold depending on the metal used. The down side of this production method falls onto the high cost of investments into such machines so production is usually held to small scale. The pressure die casting system only contains 4 main steps and produces more castings than any other method. If the dimensions and surface finish is good then the casting is considered ‘good’. The equipment first used in pressure die casting was developed in the 1830’s for producing type for the printing industry. It became popular due to its ability to make parts for home appliances and consumer goods in high volume at low costs. Zinc is the best alloy for casting due to its high impact strength and it is easily plated.

Aluminum is the next best metal used in pressure die casting. Its light weight make-up and corrosion resistance makes it an industry favorite. Magnesium stands as the easiest of all allots to machine, has an incredible weight to strength ration and is the lightest of casted metals.

Copper is highly corrosive resistant, wear resistant and impressive strength that can rate close to steel. The maximum weight limit of these alloys stands anywhere from the weakest at 10 pounds and as much as 75 pounds. Thickness is defined by the material used in the pressure die casting process. The hot and cold pressure die casting machines are the only two known to exist. The hot chamber has an attached chamber of hot molten metal attached to it and is typically used with the heavy metals.

The other model, the cold-chamber has a spate cold chamber where a specific amount of the molten liquid is injected at a time. Due to safely and health reasons the only lubricants used are water based. If the water is treated and filtered it will leave absolutely no residue on the surface of the die. The pressure die casting technology is consistently being upgraded and refined.