Die Cast Rotors

In this process, the liquid metal is injected at high speed and high pressure into a metal mould. A schematic view of high pressure die casting is given in Figure. This equipment consists of two vertical platens on which bolsters are located which hold the die halves. One platen is fixed and the other can move so that the die can be opened and closed. A measured amount of metal is poured into the shot sleeve and then introduced into the mould cavity using a hydraulically-driven piston. Once the metal has solidified, the die is opened and the casting removed. Compared to Gravity die casting, both the machine and its dies are very expensive, and for this reason pressure die casting is economical only for high-volume production. Pressure die casting is a process where metal is melted and forced into steel dies. The metal hardens into the desired shape. Molten metal is injected into a die cavity through a channel by movement of a plunger. After a preset solidification time, the plunger reverses direction, the part is ejected, and the machine is ready for the next cycle. In hot chamber casting a plunger traps a certain volume of molten metal and forces it into the die cavity through a gooseneck and nozzle. Metals having low melting points such as zinc, copper, magnesium and lead are cast using hot chamber die casting. In cold chamber casting molten metal is poured into the injection cylinder. The metal is forced into the die cavity at high pressures. High melting point alloys of aluminum and copper are normally cast using cold chamber die casting. Pressure die casting creates parts with no joints by eliminating other processes such as welding and fastening. Integral fastening elements such as bosses and studs can be included. Good dimensional accuracy and detail is possible. No further machining required usually. Casting offers low cost after amortization of tooling. Pressure die casting can produce a wide variety of complex 3D shapes provided that the shape can be ejected from the mold. Typically this requires walls with draft. Some examples of use of die casting include engine blocks, toy components, bushings, levers, gears, and assorted parts used in the automotive, aerospace and medical industries, etc.

A parting line (location where the two mold halves meet) will occur. Some flashing will occur at the parting line. Marks from ejector pins (rods that push the part out of the mold) may occur. Provide a shape that can easily be ejected from the mold. Keep wall thickness uniform.