1. Presented by: Chandra bhan prajapati 2008AMD2934

2. The casting process is subdivided into two distinct subgroups: 1 - Expendable mold casting (sand, plastic, shell, and investment (lost-wax technique) mouldings.) 2 - Nonexpendable mold casting (permanent, die, centrifugal, and continuous casting). Classification of die casting: (a)Gravity Die Casting (also called permanent mould process) (b)Pressure Die Casting

3. Die Casting Process Flow (Image courtesy: wiki)

4. [Pressure-die casting] [ pressure die Casting Techniques] [Die cast Part of automobile] [Die casting Fence fittings] (Image courtesy: wiki)

5. (Hot Die Casting machine) (Image courtesy: wiki) There are two basic types of die casting machines: (1)hot-chamber machines (2) cold-chamber machines

6. cold-die-casting machine (Image courtesy: wiki)

7. Attribute/proc ess sandinvestmentGravity diePressure die Max. size Several tons Upto 20 kgUpto 50 kgUpto 8 kg Dim. tolerance>0.6 mm>0.1 mm>0.4 mm>.05 mm Surface finish>200 rms>60 rms>150 rms>30 rms Min. thickness>6 mm>1.5 mm>4.5 mm>0.8 mm Economic quantity Any no.>100>500>2500 Table : Capabilities of major casting processes

8. ( Cooling Curve for casting) (Image courtesy: wiki) Chvorinov's rule: The local solidification time can be calculated using Chvorinov's rule, which is:

9. Structure: (Intermediate cooling rates from melt result in a dendritic microstructure. (Image courtesy: wiki)

10. Material Min. Thickness mm (in) Min. Draft Angle (º) Aluminum alloys 0.9 mm 0.5 Zinc alloys 0.6 mm 0.25 Copper alloys (Brass) 1.25 mm 0.7 Minimum wall thicknesses and minimum draft angles for die casting are :

11. Die casting materials: Zinc: the easiest alloy to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life. Aluminum: lightweight; high dimensional stability for complex shapes and thin walls;. Magnesium: the easiest alloy to machine; excellent strength- to-weight ratio; lightest alloy commonly die cast. Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance.

12. MaterialSiliconCopper Tensile Strength MPa (ksi) Properties AA 380 (UNS A03800) 8.5 %3.5 % 324 (47) Fair easy to fill AA 384 (UNS A03840) 11 %4 % 331 (48) Easy to fill AA 386 (UNS A03860) 9.5 %0.6 % 317 (46) Good corrosion resistance AA 390 (UNS A03900) 17 %4.5 % 283 (41) Good wear resistance Common aluminum alloys for die casting are summarized as follows:

13. Advantages: Excellent dimensional accuracy Smooth cast surfaces (1 — 2.5 μm rms). Thinner walls can be cast Inserts can be cast-in (such as threaded inserts, heating elements ) Reduces or eliminates secondary machining operations. Rapid production rates. tensile strength as high as 415 MPa. Disadvantages: Casting weight must be between 30 grams and 10 kg Casting must be smaller than 600 mm High initial cost. Limited to high-fluidity metals. A certain amount of porosity is common. Thickest section should be less than 13 mm A large production volume is needed to make this an economical.

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