In the hot chamber machine, the injection mechanism is immersed in molten metal in a furnace attached to the machine. As the plunger is raised, a port opens allowing molten metal to fill the cylinder. As the plunger moves downward sealing the port, it forces molten metal through the gooseneck and nozzle into the die. After the metal has solidified, the plunger is withdrawn, the die opens, and the resulting casting is ejected.

Die casting dies (Fig. 3) are made of alloy tool steels in at least two sections called fixed die half and ejector die half. The fixed die half is mounted on the side toward the molten metal injection system. The ejector die half, to which the die casting adheres, and from which it is ejected when the die is opened, is mounted on the moveable platen of the machine.

The fixed die half of the die is designed to contain the sprue hole through which molten metal enters the die. The ejector half usually contains the runners (passage ways) and gates (inlets) which route molten metal to the cavity (or cavities) of the die. The ejector half is also connected to an ejector box which houses the mechanism for ejecting the casting from the die.

Ejection occurs when pins connected to the ejector plate move forward to force the casting from the cavity. This usually occurs as part of the opening stroke of the machine. Placement of ejector pins must be carefully arranged so force placed upon the casting during ejection will not cause deformation. Return pins attached to the ejector plate return this plate to its casting position as the die closes.

Fixed and moveable cores are often used in dies. If fixed, the core axis must be parallel to the direction of the die opening. If moveable, they are often attached to core slides. Should the side of a die casting design require a depression, the die can be made with one or more slides to obtain the desired result without affecting ejection of the casting from the die cavity. All moveable slides and cores must be carefully fitted,

and have the ability to be securely locked into position during the casting cycle. Otherwise, molten metal could be forced into their slideways causing a disruption of operations. Although slides and cores add to the complexity and cost of die construction, they make it possible to produce die castings in a wide variety of configurations, and usually more economically than any other metalworking process.

Cold chamber machines (Fig. 2) differ from hot chamber machines primarily in one respect; the injection plunger and cylinder are not submerged in molten metal. The molten metal is poured into a “cold chamber” through a port or pouring slot by a hand or automatic ladle. A hydraulically operated plunger, advancing forward, seals the port forcing metal into the locked die at high pressures. Injection pressures range from 3,000 to over 10,000 psi for both aluminum and magnesium alloys, and from 6,000 to over 15,000 psi for copper-based alloys.

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Die Casting Mold Release Agent