Die Casting

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Die Casting

• By Jonathan Gordon and Lee

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• Gravity Die Casting

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Gravity die casting process

• Mazak, an alloy of Zinc and aluminium, is first
  melted in a crucible furnace.
• Molten metal is then poured by ladle in to an
  open steel mould where it is allowed to cool and
  solidify.

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Gravity die casting process

• The mould is then turned upside down and tapped
  with a hammer to release the finished casting.
• Gravity die casting requires minimal finishing
  and waste as minimal because excess metal can be
  melted down and used again.

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Things that you may recognise

• Things that are made from gravity die
  casting are
• Toaster -
• Lawnmowers -
• Car wheel rims -

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Identifying the process

• When something has been created by gravity
  pressure die casting there would be
• Section hair lines
• ejector pin marks
• sprue and runner marks

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Materials

• The materials used in gravity die casting is a
  mixture of Zinc and aluminium.
• Zinc -
• Aluminium -

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• High pressure die casting

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High Pressure Die Casting

• Forcing metal under high pressure to form a
  mould.
• These moulds are called dies and are made from
  steel.
• This produces non-ferrous metals.

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Materials used

• Metals that are commonly used are also
• Aluminium -
• Zinc -

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What is made from the process

• In this process you can make
• Golf club heads -
• Car engine blocks -
• Radiators -

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High pressure die casting process

•  First the mould is sprayed with lubricant
  and closed.
• Molten metal is then injected into
• the mould under high pressure.

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High pressure die casting process

• Once the cavity is filled, the pressure is kept
  at a steady level until the casting has become
  solid.
• Finally, the die is opened and the casting
• is injected.

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Identifying the process

• When something has been created dy high pressure
  die casting there would also be
• Section hair lines
• ejector pin marks
• sprue and runner marks