The Die Casting Process in 5 Steps – How it Works

ion and aids the removal of the cast once it has set.

The die halves can be closed and clamped tightly together using high pressure.

Step 2: Injection

Following this preparation stage, molten metal is then taken from a furnace and ladled directly into the die via a downward sprue. This can either be done manually or, in some circumstances, using an automated ladle; but either way, the process takes advantage of gravity. No additional forces or pressures are applied. The molten liquid is simply inserted into the die from an upright, vertical position and it makes its own way down into the cast due to the natural pull of gravity.

By avoiding the use of high-pressures, turbulence is significantly reduced and this – in turn – helps to prevent porosity and leads to the production of much smoother components and parts.

Step 3: Cooling

Once the molten metal has been inserted into the cast, it is then left to cool and solidify. The metal should be given sufficient time to take the shape of the mould and it needs to be completely set before the die is unclamped. Removing the cast prematurely can lead to irreversible defects.

Step 4: Ejection

After a sufficient period of time has passed, the die halves are then unclamped and opened, and the cast parts are carefully removed. This can either be done by hand or, in some situations, ejector pins are used to push the cast safely out of the gravity die casting machine.

Step 5: Trimming

The final stage of the gravity casting process is trimming. As the metal continues to cool, any scrap metal – including the gate, runners, sprues, and flash – are expertly removed from the casting. A variety of tools are used to take away any sharp edges and excess material, thus creating the desired component shape, and the part is usually cleaned before despatch to the customer.