Die Casting

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					?Die casting is a process in which various metals can be cast from molten states into a
mould. These moulds are called "dies" in many foundry environments. The die is
filled with typically non-ferrous metals, such as zinc and aluminium. It is filled in a
high-pressure application that ensures that the density of the die-cast material is at the
desired level.

The metal is injected into a specific cavity or mould that has been created. This is then
machined to create two opposing steel dies. After the cooling process is completed,
the casting is then removed from the mould. It is next burred or buffed to create a
product that has been manufactured to exact specifications.

The process of die casting has evolved since its original inception to become much
more efficient, in terms of both production and a decrease in the creation of scrap
materials. When the molten metal is injected into the mould, this shot uses between
1,500 pounds (680.39 kilograms) to over 25,000 pounds (11,339.08 kilograms) per
square inch of pressure. This is to ensure that the entire mould is filled with material
to create consistent and full mould shots. The term shot refers to each mould being
injected, since there can be multiple moulds within a mould casing, and multiple
castings produced within a shot.

Die casting has long been a valuable means of producing hardened metal products,
such as engines. Many other items are also cast into moulds from molten states, such
as cast-iron pots and pans, and other car parts. This method of production has been
used in industrial settings to create a multitude of different products, mainly because
the casting process is able to produce parts of virtually any size and shape, depending
on the mould that has been created for the metal to be poured or injected into.

Virtually any part that is needed for a specific application can be cast from almost any
metal. One of the most popular, however, is aluminium. The low melting point and
the ease of machining applications with aluminium make it an easily manipulated
material to work with. This, in turn, results in a lower cost of production.

Due to the increased initial cost for the die casting equipment and the facilitation of a
die casting operation, most of the industrial environments that have these types of
productions take place do so on a large or heavy production scale. This is especially
true in the automotive industry. There, the bulk of many automobile engines are made
out of cast metal parts.
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