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Posts Tagged ‘alloy castings’

The first of 14 videos showing how to make alloy castings in a home made foundry.
Part one shows how the mould is made and in part two the metal is melted and poured.

High pressure die casting enables economical quantity production of castings at a fast rate. These castings can comprise of varied holes, screw threads, recesses, and are identified by a high dimensional accuracy and good surface finish. They enable good economy of metal and need very little surface finishing. The principal on which pressure die casting is based, includes forcing molten metal into a mold or the die, under considerable pressure. The machines which are used for this reason operate on one or two systems :

* Hot Chamber Machines ( for metals with a low softening point )
* Cold Chamber Machines ( for metals with a high softening point )

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In the hot chamber machines the metal is kept liquid in a crucible within the machine, and the pressure chamber that delivers the metal into the die is located in the metal bath. This machinery can be pneumatically operated, or more sometimes develop the pressure by the action of a ram. The casting metal for a cold chamber machine, is kept liquid in a holding furnace, from which it is moved to the pressure chamber, by means of a scoop or a special automatic device and is forced into the die by the way of a ram. Some straightforward machines are hand operated, but fully automatic machines are far more frequently employed for high rates of production.

In pressure die casting, precision made dies of complex multipart design and so extraordinarily dear are used, and exposed to severe conditions of work, by high pressures and high successive variations in temperature. For the production of zinc and zinc alloy castings the dies may be made of unalloyed steel, however for magnesium, aluminum, copper and the alloys of these metals, the dies are often made from hot-work steel, that has much greater sturdiness.

Another development in high pressure die casting is vacuum die casting. It produces castings which have an even better finish than standard high pressure castings. There are two systems, the die is either enclosed in a hood which abandons the air, or the holding furnace is installed under the casting machine, so that on the evacuation of the air from the die, the metal is sucked into the die and is compacted in it, and a process for making iron castings based on this principle has been developed..

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