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A precision casting technique, die casting uses a permanent die or mould, into which molten metal is directly discharged. Along with gravity feed system, metal is consistently forced into the mould under high pressure. As per the cost incurred in the designing of dies, tooling and other capital costs are relatively high as compared to other operational costs. Die casting is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel molds. These molds, called dies, can be designed to produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes.

Process :

In the entire procedure, firstly the molten metal is inserted into the die and held under pressure until it cools and dries. To assist ejection and improve surface quality, the die is cleaned between each casting cycle, preheated and lubricated. The molded coating material is also applied to preserve the molten metal from conductive and cool veneer of the mould. Often, cooling systems are used to sustain the desired operating temperature.

Selecting the Right Metal Casting Process

• Special requirements such as, magnetism, corrosion, stress distribution also influence the choice of the Metal Casting Process.
• Views of the Tooling Designer; Foundry / Machine House needs, customer's exact product requirements, and secondary operations like painting, must be taken care of before selecting the appropriate Metal Casting Process.
• Tool cost
• Adequate protection / packaging, shipping constraints, regulations of the final components, weights and shelf  life of protective coatings also play their part in the Metal Casting process.
• Economics of machining versus process costs.
• For any Metal Casting Process, selection of right alloy, size, shape, thickness, tolerance, texture, and weight, is very vital.

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