Alloy Tech, Bangalore

Anekal, Bangalore, Karnataka

In die casting, molten metal is injected into a mold at a high pressure. The pressure can range from about 1, 400 psi to as high as 30, 000 psi. By pressurizing the mold, the cast object will be more uniform and will display an attractive finish. In many cases very little or no post-casting machining is needed to complete the item. Pressure molding also provides for precise dimensional accuracy that is critical for parts used in products with interchangeable parts. Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. Die-casting can be done using a cold chamber or hot chamber process. Die-c In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures.

Aluminium casting processes are classified as Ingot casting or Mould casting. During the first process, primary or secondary Aluminium is cast into rolling ingot (slab), extrusion ingot (billet) and wire bar ingot, which are subsequently transformed, in semi- and finished products.

The second process is used in the foundries for producing cast products. This is the oldest and simplest (in theory but not in practice) means of manufacturing shaped components.

High-pressure die-casting is a process we use to make aluminum die cast parts. We inject molten aluminum alloy metal under pressure into a steel die to produce aluminum parts. Die-casting is a very inexpensive aluminum part manufacturing process.

When the molten metal is injected in the mould, the metal solidifies at a very fast rate. The metallurgical structure and different metallic phases have not the time to find equilibrium in the material. After the part has cooled down to room temperature, the ageing process in the metallic structure is starting. The different phases begin to move to their equilibrium state. With this movement, internal stresses are relaxed resulting in loss of hardness, loss of tensile strength properties and increase of ductility (elongation propertie

In die casting, molten metal is injected into a mold at a high pressure. The pressure can range from about 1, 400 psi to as high as 30, 000 psi. By pressurizing the mold, the cast object will be more uniform and will display an attractive finish. In many cases very little or no post-casting machining is needed to complete the item. Pressure molding also provides for precise dimensional accuracy that is critical for parts used in products with interchangeable parts. Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. Die-casting can be done using a cold chamber or hot chamber process. Die-c In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures. In a hot chamber process the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures. Die casting molds (called dies in the industry) tend to be expensive as they are made from hardened steel-also the cycle time for building these tend to be long. Also the stronger and harder metals such as iron and steel cannot be die-cast.

Aluminium is a silver colored metal with lightweight properties, making it good for certain construction. Industrial aluminum is used worldwide and its production and supply heavily influence economics everywhere. Aluminum alloys are also produced for use in machinery, automobiles, and as a chemical additive. Engineering aluminum can be tricky, and requires an experienced technician who has dealt with the metal. An aluminum castings manufacturer can create specialty parts. An alloy is a material made up of two or more metals. Alloys are designed and produced having certain specific, desirable characteristics, including strength, formability, and corrosion resistance. Some of the common elements alloyed with aluminum include copper, manganese, silicon, magnesium and zinc. Typical applications and uses of aluminum alloys include building products (siding and structural), rigid and flexible packaging (foil, food and beverage cans) and transportation (automobiles, aircraft, and railcars). Aluminium alloys are readily fabricated. They are amenable to all casting processes. They can be rolled to any desired thickness with pure aluminium foil production down to the thickness of 6m. A wide range of forgings are produced using extruded and cast bar and standard forging equipment. There is almost no limit to the different shapes to which the metal may be extruded. All of the aluminium alloys are easily machinable by standard techniques such as turning, milling, boring etc. Adjustment needs to be made to machining speeds and cuts when machining both cast and wrought product if the optimum finish is to be achieved.