Type Of Casting Process

1.
2.
3.
4.
5.

Sand Casting
Plaster Mould Casting
Investment Casting
Shell Molding
Die Casting

Sand Casting
Sand casting is the simplest method of casting aluminum. Sand is made
into a mould by forming around a wooden "pattern". The pattern is
removed, the sand mould assembled and molten metal pored in. The
process is chosen for small production runs, for complex shape
castings requiring intricate cores or for very large castings.
Advantages
Low equipment costs
Largest size of castings possible by any casting method
suited to complex shapes and cores
Very low gas porosity is possible
It is a versatile casting process
Limitations
Low casting rate
3-5mm minimum wall thickness
Poor linear dimensional tolerances e.g. 4mm / m
Rough surface finish
Coarse grain size compared to die casting
Casting weights in the range of 0.1 Kg - 100,000 Kg
Approximate economical quantity range 1 - 1000 castings.

Plaster Mould Casting

Permeable plaster moulds give a smooth
surface finish (80~125 rms) with a finer
surface detail than is obtainable with shell
moulds. Castings as thin as 0.5 mm are
possible. Slow solidification rates reduce
internal stresses so that any casting distortion
is negligible.
Machining and finishing operations may be
eliminated by the use of plaster moulds. Small
holes may be cast to size ready for tapping.
Surface finish and dimensional accuracy
equates to die casting qualities. LM25 alloys
are commonly cast by this process.

Investment Casting
This casting method involves producing a "wax
pattern" by injecting wax or plastic into a
pattern die. The pattern is attached to gating
and runner systems and this assembly is
dipped in a hard setting refractory slurry,
which is then cured. The pattern is melted
out of the mould to leave an exact cavity. The
mould is heated to cure the refractory and to
volatolize the remaining wax pattern
material. The moulds are baked and molten
metal is poured into the mould cavity. On
solidification of the casting, the mould
material is broken away from the castings.

Shell Moulding
A shell mould consists of a sand shell, varying in thickness
between 4-10 mm. The sand particles are bonded
together with phenolic resins giving a permeable mould.
The production of shell moulds may be automated which
lends itself to medium to high production runs. The resin
coated sand is placed on a hot metal pattern; this is fired
in an oven to harden the shell. After cooling, the shell is
removed from the pattern and is ready for use. Molten
metal is then poured into the shell mould cavity and
allowed to cool. The mould material is broken off the
casting. Better dimensioned tolerances are possible than
with sand moulding, which reduces machining costs. Fine
surface finishes equal to that of permanent moulds
(12~130 rms) may be obtained. and consistently
reproducible thin castings with fine detail may be made.
The process is more costly than sand, permanent mould
or die casting.

Die Casting
Liquid metal is introduced in metallic molds!
The injection of metal could be:
1. Under influence of high hydraulic pressure
with the die loaded on machine (HPDC).
2. Under influence of low pneumatic pressure
with the die loaded on machine (LPDC).
3. Under influence of Gravity (Poured by
hand) in a stationary mold, called GDC.
4. Under influence of Gravity (Poured by
hopper) in a tilted mold and subsequently
straightened, called Durville Process

Why Pressure Die casting ?

The decision to choose Pressure Diecasting as
the preferred production method is generally
driven by a requirement for high annual volume.
As the annual demand increases, the lower piece
part price offered by the pressure diecasting
route results in a far cheaper "Total Project Cost"
than other methods of casting Aluminium.
The diagram below indicates that should the
volumes required be low, then the case for
gravity diecasting or sand casting becomes
increasingly strong, due to the low start up costs.

Types Of Die Casting

High Pressure Die Casting ( HPDC)
Low Pressure Die Casting (LPDC)
Gravity Die Casting (GDC)
Vacuum / high Vacuum Die Casting

High Pressure Die Casting

Pressure die casting is a repetitive process casting identical parts by injecting
Aluminum into metal moulds at pressures in the order of 1000psi. Complex
machinery and expensive tooling is required for this process.
Advantages
Production rates may be in the order of 200 / Hr
Thin wall thickness at 1 - 2.5mm
The best surface finish is produced by this method
Very fine grain structure is obtained
The castings have high strength in the as-cast condition
Good linear tolerances and repeatable properties are obtained
Limitations
Size of castings limited by the machine
Sound, thick sections are difficult to cast
Core configuration may be complex to enable disassembly
Porosity may become a concern
High start up costs require long production runs to reduce the overall cost
Castings cannot be heat treated
casting weight range 0.01 Kg - 25 Kg
Approximate economical quantity range > 10,000 per annum.

Low Pressure Die Casting

This is a repetitive process where identical parts are cast by injecting molten
metal under low pressure into metal dies. This process requires complex
machinery and is similar to high pressure die casting.
Advantages
Fair production rates up to 30 / Hr
Thin wall thickness possible ( 2-3mm)
Better linear tolerances than gravity casting
surface finish improved on gravity casting, but not up to pressure die casting
standards
High Yields possible as runners and risers not required
Reduced finishing is required
Pore free castings are obtainable
Sand cores may still be used to allow complex castings
die costs far lower than for pressure die casting
Castings are heat treatable
Limitations
Size of casting limited by machine size
Production rates not up to pressure die casting
Feeding thin sections through thick sections is not recommended
casting weight range 5 Kg - 25 Kg
Approximate economical quantity range >1000

Gravity Die Casting

Castings are produced by poring molten metal into permanent metal
moulds. (Generally made from Cast Iron).
This process produces 'Chill Castings
Advantages
Lower set up cost than Pressure Die casting
Higher casting rate than sand casting
Low gas porosity levels are possible
Fine grain sizes may be obtained
The highest quality castings with regards to mechanical integrity can be
produced by this method
Less finishing is required than for sand castings.
Limitations
Minimum wall thickness 3-5mm
Linear tolerance is approximately 3 mm/m
Surface finish better than sand casting
The complexity of possible casting shapes is limited
Casting weight range 0.1 Kg - 70 Kg
Approximate economical quantity range 500 - 2500 (This may increase
where sand cores are used to produce shapes impossible with pressure
die casting.)

Vacuum and high Vacuum Die

casting
The porosity sets
the limit to
the conventional
casting
Limited heat treatable
Limited weldable
The die can be vented with
the support of a vacuum

The Quality is increased

with a moderate vacuum
between 200 and 500 mbar

Vacuum and high Vacuum Die

casting High vacuum lower
than 50 mbar

Dosing

Start
Evacuation

Turbulence-free filling

Additional measures

Die concept (sealing)

Die spraying
Melt treatment
Metal dosing

Valve closing
Intensification

Vacuum and high Vacuum Die

casting

Requirements to structural parts

Rp0,2

120-150 Mpa

Rm

>180 Mpa

A5

>15%

Vacuum and high Vacuum Die

casting
Additional advantages

Cast parts are easily heat treatable and weld able

High mechanical properties are reachable

High consistency of this properties

Expensive but high quality alloys can be cast economically

Vacuum and high Vacuum Die

casting
An entire new part
spectrum for the
die caster

Typical vacuum
die cast parts

Space frame node

Climate control

Advantages of Die Casting

Mass Production Process
Consistent quality over mass production
Least dependence on human skill Higher
engineering strength of materials

BUT
It is an energy
intensive process
Continuous energy
input is a
PREREQUISITE!

And Energy is
going to be ever

COSTLIER!

Aluminum
is the most widely used
metal for die casting!

This is because:
It responds well to mold filling
It is light in weight
Its thermal properties are excellent
Its engineering strength is
comparable with steel.
It is non-corrosive hence longer
functional life.

BUT
At higher temperature it has:

Affinity for oxygen (oxide formation)

Affinity for hydrogen (causing gas porosity)
Oxidation causes metal loss
Porosity causes rejection
Facility to control melting, holding of metal
and casting parameters is essential!

Other Metals Used In Die

Casting
1. Magnesium
2. Brass
3. Zinc

Initial cost of
equipment to melt and
hold liquid metal is
high!

Investment is
called for in
Quality Assurance
and Energy Saving
Activities!

High Pressure Die

Casting!

Casting parameters are

best controlled by this
process!

It is also the most

productive process of
casting with least energy
consumption

Because
Casting process is carried out on machine.
Modern machines are equipped with strict
casting parameter controls.
Strength of castings, thus produced, is high.
Rejection is least.
Any deviation from set parameters is reported
by audio signal and further production is
halted.
Deviation report is available on
microprocessor hence quick rectification.

BUT
It does not accept any collapsible mold (e.g. Sand
Cores)
Each machine is designed for a specific range of
casting size!
Larger castings cannot be made on a smaller
machine size.
Smaller castings can be manufactured on larger
machine size using multi-cavity mold scheme.
Multi-cavity mold scheme is justified for large and
constant quantum off-take.
Such machines are costly!
Levels required of plant cleanliness and tool &
machine maintenance are high.

Some facts
Modern Casting Purchasers
1.
2.
3.
4.

Envisage excellent capability of vendor to produce

large series.
Expect in-time casting delivery of goods.
Presume High and Consistent Quality & Productivity
Standards.
Encourage only those vendors with ISO Quality
Certification.

ISO Quality Certification necessitates

strict parameter control and
Documentation thereof.

Market Prospects
HPDC Castings are mainly
consumed all over the world by:
1. Automobile Industry
2. Electrical & Electronic Industry
3. Communication Industry (Mobile
Phones, Laptop Bodies, etc.)

Export Market for the

die cast products is not
exploited at all by
Indian Die Casting
Industry!

All this for the

fear and
magnitude of

Initial
Investment!!!

Installing HPDC Capability

requires
Excellent marketing
strategy
Strong financial capability
Alert Purchase Policy
Accurate choice of
machines
Selective customer base
Customers requiring large
series quantities
Customers with good
credit rating
Uninterrupted energy
supply

High tool design

capability
Equipment to closely
control production
parameters
High maintenance
standard
Limited, yet skilled,
manpower
Strong and alert
marketing personnel
Efficient accounting
system

Conclusion

Advantages
High productivity
High dimensional accuracy
Good surface; polishable
Near net shape
High strength of the surface
layer
Inserts, composites casting
well
realizable
Very economical with large

Disadvantages
Pore-free structure difficult to
produce
High investment costs
Limited freedom in design
Low elongation
Castings only limited heat
treatable and weldable
Decorative coatings
almost impossible

Pressure Die Casting

Process is Economical

When

1. Large Quantum Production is envisaged

2. High Quality of produce over large quantum
is the requirement
3. Machine down time due to lack of
contracts is least
4. Machine down time due to breakdowns is
least
5. Material purchase cost is well controlled
6. Technical parameters are strictly adhered to.

Good luck!

Conventional
die castingdie
The conventional
casting is one of the most
economical casting process
Venting slots

Dosing of metal
from the top

Die filling
real-time controlled

Die opening
ejection of die casting