New Casting Equipment--Low Pressure Die Casting

Low pressure die casting is used fill the molten metal into the mold. In low pressure die casting, the die is filled with metal from a pressurised furnace, with pressures typically around 0.7 bar. The holding furnace is positioned in the lower part of the vertical die casting machine, with the molten metal injected upwards directly into the bottom of the mould.

Low pressure die casting vs High pressure die casting

The different capabilities and restrictions of high-pressure and low-pressure die-casting processes need to be taken into account when choosing a method of production to meet your component requirements. Low-pressure die-casting accounts for around 20% of light metal casting but, the most commonly used is high-pressure die-casting which accounts for around 50% of light metal casting.

Low pressure die-casting primarily uses alloys with low melting points and allows for the production of components up to around 150 kg. The advantages are very high strength and the ability to form complex geometries, whilst maximising material usage.

The process is less suitable for very thin-walled parts where the required thickness is less than 3mm. Low pressure die-casting is also relatively slower than those components produced in high-pressure processes. Machine size will also limit the size of castings.

On the other hand, high pressure die-casting, which is most commonly carried out in soft alloys such as zinc and aluminium. The molten metal alloy is pressed into the mould under high pressure and at high speed, which allows for much quicker casting production. High-pressure can provide thinner cross-sections than any other casting process, with wall thicknesses under 0.40mm depending on the size of your component and requirements.

High-pressure casting will also provide smoother surfaces for finishing options. Surface finish depends on the quality of finish on the dies. This high-quality finish enables other coatings to be applied directly.

The disadvantage, however, is that high operating and investment costs are incurred. You also need to consider that machine size will limit casting size.

With high-pressure production, thick sections can be difficult to cast. High-pressure die-castings may also suffer from porosity, although working with your supplier there are methods to improve this. It is also worth noting that high start-up costs are only reduced by high volume production requests.