Among the many manufacturing techniques for high volume parts to choose from, pressure die-casting is a metal casting process that is by far the quickest, cost-effective, and reliable. It can manufacture metal parts that require tight tolerances too.

There are many types of pressure die-casting, but the most familiar of them is high-pressure die-casting. It is a traditional die casting method that entails injecting the molten metal material into a three-dimensional mold.

The metal can be zinc, aluminum, lead, steel magnesium, and many more. In the process, the metal is heated until it is molten. Then it is forced into the mold’s cavity and allows it to take the shape of the mold and cure.

There are plenty of uses for high-pressure vacuum casting. From engine blocks to airplane components, including heavy-duty fasteners. In this article, we are going to discuss the four steps involved in the high-pressure die-casting method.

How High-Pressure Die-Casting Works?

In the high-pressure die casting process, molten metal or an alloy of metal is injected into the mold with the application of speed and pressure. Using high pressure ensures that the die is completely closed. The pressure is rated by how much force is applied to closing the mold. It can be between 550 to 5700 tons.

The mold where the molten metal is injected can be a hot or cold chamber. In hot chamber die casting, the molten material is contained in the die casting machine and is drawn into the chamber and forced into the die using the built-in injection piston.

Meanwhile, in the cold chamber process, the metal is melted in a separate container and transferred into the furnace and the shot sleeve before it is injected into the mold.

Steps Involve in High-Pressure Die Casting

While there are different ways to perform high-pressure die casting, the processes involved are always the same. Here are these steps.

- Preparing the Mold

Just like in any other manufacturing process, the first step in die casting involves preparing the mold. During the prep work, an application of a lubricant is required to regulate the temperature of the mold and also creates a film between the mold and the molten material for easy removal after the part has cured.

- Injection

Once the mold is prepared, the next step is injecting the molten material into the mold. By applying pressure, the mold is tightly closed and sealed. The molten metal is injected between 1,500 to 25,000 lbs per square inch. The preparation will be maintained until the curing process is completed.

- Ejection

The next step in the die casting process is ejecting the cavity from the mold. This mold has ejector pins that release the cavity. It should be done when the part is already cured and solid enough to be removed from the cavity.

- Shakeout

The final step in high-pressure die casting is the shakeout. The technician removes any scrap metal remaining on the cavity. Not all of the molten material will be included in the casting process and it should be removed before the mold is reused.

Conclusion

In summary, high-pressure die casting is a four-step process. It is a natural progression of steps that you can find in other manufacturing processes. Thus, the steps are almost the same as any injection molding technique, only the application pressure and choice of material used are different.