Die Casting

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Die Casting
Material Science

• Developments in dies

Annamalai Industrial Engineering
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Die casting process

• Molten metal is injected under high pressure into
  a steel mold (die).
• Rated in Clamping tons
• Amount of pressure they can exert on the die
• Capacity 400 tons to 4000 tons

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Alloys

• Aluminum magnesium
• Substitute for ferrous casting (automotive
  sector)
• Weight reduction
• Magnesium titanium
• Automotive Aerospace markets
• Aluminum lithium alloys
• Meeting requirements in aircraft industry
  (reducing structural weight).

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Surface Coating
Plasma assisted Chemical vapor deposition (80000
casts against hard chrome 10000 casts).
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Ceramic composite die

• A unique nitride / nitride carbide matrix
• Half the weight of conventional steel dies 10
  times the useful life.
• Proven stability to molten metals, resistant to
  corrosion, erosion, oxidation, thermal fatigue
  and cracking.
• Materials Electrochemical research corporation
  MERC

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Titanium matrix composite tooling

• CermeTiTM
• Implemented in the form of shot sleeve or a
  partial liner inserted into an existing H13 shot
  sleeve. (minimum 4 times cast life).

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References

• www.science.doe.gov
• www.diecasting.org
• www.oit.doe.gov