Section7Processing-LearnEASY.info.docVIP

Section 7: Processing From /processes/processes_home/process.cfmAnd The Open University Walton Hall, Milton Keynes MK7 6AA Hot FormingProcessesDie CastingSand CastingExtrusionForgingPowder MetallurgyCentrifugal Heat TreatmentsAnnealingTemperingDirect HardeningSelective HardeningDiffusion HardeningStress RelievingOverview Cold FormingProcessesCold RollingStakingBurnishingImpact Extrusion Surface TreatmentsElectroplatingElectroless PlatingConversion CoatingThin-Film CoatingThermal SprayingHigh Energy Treatments MachiningDrillingReamingTurningMillingGrindingChip Formation Rapid PrototypingStereolithographyLaser SinteringFused DepositionSolid Ground CuringInk JetRapid Tooling Sheet MetalProcessesLaser CuttingCNC FabricationBendingStamping? (Blanking, Drawing, Piercing)Welding CASTING 1. Die Casting - (or Pressure Die-casting) The metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) psi . This gives a more uniform part,?good surface finish and?dimensional accuracy, (around 0.2 % of casting dimensions). Can almost eliminate?post-machining on some parts.?Die casting molds (called dies in the industry) are expensive as they are made from hardened steel and take a long time to make. There are two types of die-casting - cold chamber or hot chamber process. ? ??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 (which will wear out the plunger cylinder). The largest die-castings are about 20 kg? for Magnesium (35 kg for Zinc). Large castings tend to have greater porosity problems, due to entrapped air, and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. Vacuum die casting redues porosity.? ??Hot chamber p