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The Four-Key Step of High-Pressure Die Casting

by Nice Rapid | Mar 24,2021 | Die Casting

High-pressure die casting has slowly emerged as one of the best manufacturing techniques when it comes to the production of a wide range of products and parts used in various sectors. Also referred to as traditional casting, high pressure die casting is a metal casting technique that involves the injection of molten metal which is normally steel, zinc, copper, aluminum, lead, magnesium just to mention a few forming a three-dimensional mold.

The base mold is heated using extremely high temperatures till it turns into a liquid molten state, it's then forced onto the mold cavity which enables it to form a desired shape and design once it's cooled.

High pressure die casting is normally used in a wide variety of applications, most of the things that you see daily are probably made from high pressure die casting. From heavy-duty fasteners to aerospace components as well as engine blocks; these are some of the few things created using high-pressure die casting.

die casting products

While there are different ways of application and usage of high-pressure die casting, here are some of the four steps that are followed globally.

1. Preparation of the molds

One of the first and most obvious steps in the preparation of the mold, during this step most workshops and manufacturers apply lubricants onto the interior walls of the mold, this is quite significant as the mold plays a crucial role in the regulation of the mold's temperature as well as creating a film barrier between the molten metal and the mold which allows for faster removal of the casting making the entire process fast, efficient and seamless.

2. Injection

After the die mold has been prepared, it's then injected with the molten metal. For this step, you must pay special attention to ensure that the mold is completely sealed and closed, otherwise, if this isn't done it won't be able to fully receive the highly pressurized molten metal.

Depending on your application and usage, the molten metal is injected onto the mold with pressure ranging from 1,500 to 25,000 pounds per square inch (PSI). There will be the maintenance of this pressure on the molten metal till it fully cools and solidifies.

3. Cavity ejection

The next phase is the ejection of the brand-new cavity from the mold, the mold is normally designed with ejector pins which are engaged allowing the release of the cavity. The cavity must have fully solidified for it to be ejected.

If the molten metal is still in liquid form, then you must wait till it fully solidifies for the cavity to be fully ejected.

4. Shakeout

The 4th and final step of high-pressure die casting is shakeout. During this phase, any form of scrap metal is separated from the newly-formed cavity. It's not uncommon for this technique to produce metal scraps. This scrap metal must be removed before the mold can be reused before its life cycle ends. 

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