Die Casting

1. Die Casting By Jonathan Gordon and Lee

2. Gravity Die Casting

3. 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.

4. 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.

5. Things that you may recognise • Things that are made from gravity die casting are: • Toaster - • Lawnmowers - • Car wheel rims -

6. 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

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

8. High pressure die casting

9. 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.

10. Materials used • Metals that are commonly used are also: Aluminium - Zinc -

11. What is made from the process • In this process you can make: • Golf club heads - • Car engine blocks - • Radiators -

12. 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.

13. 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.

14. 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