Taharqa, King of Kush and the Assyrians by Dan'el Kahn

By Dan'el Kahn

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By Dan'el Kahn

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25–3 , depending on section depth. Maximum section ¼ 13 mm. 5 mm for copper alloys. Sizes ranging 10 g–50 kg. Castings up to 100 kg made in zinc. Copper, tin and lead castings normally less than 5 kg. Quality issues . Low porosity in small castings typically, but can be a problem in castings with thick or long sections. Particularly suited where casting requires high mechanical properties or absence of creep. 2003 2:05PM Pressure die casting 47 . . . . . The high melting temperature of some metals can cause significant processing difficulties and die wear.

Draft angle ranging 2–3 . Maximum section ¼ 50 mm. Minimum section ¼ 2 mm. Sizes ranging from 50 g to 300 kg in weight. Commonly used for castings less than 5 kg. Quality issues . . . . . Little porosity and inclusions: can be minimized by slow die filling to reduce turbulence. Redressing of the dies may be required after several thousand castings. Collapsible cores improve extraction difficulties on cooling. ‘Chilling’ effect of cold metallic dies on the surface of the solidifying metals needs to be controlled by pre-heating at correct temperature.

Molten metal is poured under gravity into a pre-heated die, where it solidifies. The die is then opened and the casting ejected. 3F). 3F Gravity die casting process. Materials . Usually non-ferrous metals, for example: copper, aluminum, magnesium, but sometimes iron, lead, nickel, tin and zinc alloys. Carbon steel can be cast with graphite dies. Process variations . . Dies typically cast iron, graphite or refractory material. Metal or sand cores can be used although surface finish can be poor.

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