High pressure die casting is a process that helps in making some components like toy parts, blocks of engine, levers, gears, bushings, parts used in automotive, medical equipment, aerospace etc. If you are involved in any manufacturing or using any of these products, then there are certain things related to die casting that you should be aware of. Pressure die casting melts a metal and forces it into steel dies. At the time of hardening, the metal can be moulded into any desired shape that can fit into the part it is made for.
On interesting aspect is that it eliminates the processes like welding and hence makes the part without any joints. It gives a superior and accurate dimension, smoother surfaces, and higher quantity of products / parts. Machining is only required for removing holes and flashes around the edges. It enables inserts to be cast-in, tensile strength ranging to 60 ksi, casting metal with low fluidity etc. While one of the very common disadvantages is the high investment, but once a pressure die casting tool is made, the cost of manufacturing parts in huge volume will come down. The die casting machines are provided by manufacturers that can be customized as per the users’ requirements.
The use of right lubricant is important for safety of the process. You should use water – based lubricant so that it can be treated to remove the minerals. The minerals, if not removed, can damage the surface and cause discontinuities. Although, the oil based lubricants can be easier to apply but it builds up carbon on the cavity walls of the moulds.