What is Medium Pressure Die Casting?
Medium pressure die casting is a manufacturing process in which a metal mold is filled up by the molten metal at medium pressure. The usual pressure applied during the medium pressure die casting process ranges from a minimum of 3 and a maximum of 100 MPa (megapascals).
The overall pressure applied during this process is in between the High-Pressure Die Casting (HPDC) and Low-Pressure Die Casting (LPDC). Manufacturers use it for making complex parts because it provides high precision and quality-oriented finishing. Moreover, a medium-pressure die-cast is mostly cost-effective and durable.
What is the Process of Making Medium Pressure Die Casting?
The medium pressure die casting process is quite simple and straightforward. Here is the detailed breakdown of all the steps below.
Mold Designing:
At first, a mold is designed typically with steel as per the exact geometry of the requirements. Cavities, cores, and other intricate details are added to the mold design in this phase.
Mold Melting:
In a furnace, selected metal alloys like zinc, aluminum, or magnesium are melted. The metal is melted until the desired temperature or other considerations like consistency are met.
Molten Metal Injection:
Firstly, molten metal is injected into a holding furnace and then into the mold. As mentioned earlier, this operation is performed at a medium pressure to ensure its properties.
Cooling and Solidification:
After the mold is filled completely, it is set to cool down. In this regard, the cooling time plays a significant role as it is responsible for the proper solidification. It also prevents defects from occurring within the die-casting product.
Ejection of Casting:
As the metal colds in and solidifies, the part of dragging it out of the mold comes in. By now, the metal has completely formed its shape. However, at some points, the metal might also be hot therefore it is carefully handled.
Finishing:
In the end, some trimming and finishing steps are applied over output metal to ensure that no excess material like flashes has been formed onto them. This step is necessary to make sure it abides by the design requirements.
Quality Control:
Finally, an inspection is performed to observe the overall product quality, surface finishing as well and structural integrity. If any deviations are found, those are immediately addressed.
What is the Difference between Medium Pressure Die Casting and Sand Casting?
The major difference between sand casting and medium-pressure die casting is that in sand casting, the mold is created through sand. It is perhaps the oldest form of die-casting. However, the key differences between these two are as follows.
Process Complexity:
Medium-pressure die casting is more of an automated and precision-oriented process whereas sand casting is a traditional and labor-oriented process. Therefore the complexity and quality of medium pressure die casting is considered more than that of sand casting.
Material Selection:
Commonly, non-ferrous metals like zinc, aluminum, and magnesium are used in medium pressure die-cast for high precision and reliability. On the other hand, sand casting can also use ferrous metals like steel and iron along with other non-ferrous metals.
Tolerance and Precision:
Medium-pressure die casting is used for high tolerances and high precision. Exact dimensions and intricate geometry requirements like in aerospace and automotive components are developed through medium-pressure die cast.
Sand casting, on the other hand, provides less accuracy when compared to MPDC. If rougher finishes are acceptable then Sand Casting is used.
What are Its Applications?
Due to its high-quality precision and absolute efficiency, which has numerous applications some prominent ones are mentioned below.
Automotive Industry:
From engine components like cylinder heads, pistons, etc. to transmission components, most of the complex automotive industry parts are made through medium-pressure die cast.
Aerospace Industry:
Aircraft components including turbine blades and other structural and spacecraft components are also manufactured through medium-pressure die cast conveniently.
Electronics Industry:
Most of the electric devices and components are made through it even the heat-resistant electronic connectors or cases. Moreover, complex electronic parts like heat sinks, etc. are also manufactured through medium-pressure die-cast.
Consumer Goods:
It is used to manufacture high-quality consumer goods ranging from cookware, to camera bodies, and other items that require extreme durability and precision perfection.
Medical Equipment:
In areas of the medical field where accuracy and high precision are required like in surgical instruments and diagnostic machine components, medium pressure die casting is used. Biocompatibility is also a major feature of it which makes it the best choice.
What are Its Benefits?
There are numerous benefits of medium-pressure die casting and some of the primary ones are as follows.
High Precision:
The dimensional accuracy and repeatability of medium-pressure die cast are remarkable. No matter how much tight tolerance comes with design requirements, it can accommodate them easily.
Improved Surface Finishing:
As compared to various other casting methods, it comes with a variety of smooth surface finishing options. It also reduces porosity as well as minimizes the chances of defects in the long run.
Design Flexibility:
Medium-pressure diecast can easily manufacture lightweight designs with thin walls suitable for specific engineering requirements. Therefore, it serves the best for applications where flexibility of design is required.
Cost Effective:
It maintains a balance between cost and manufacturing speed thus making it possible to be manufactured through medium to high-volume production lines. The cost of medium pressure die-cast is economical and feasible.
Reduced Material Waste and Post Processing:
Compared to other casting processes, it offers a significant reduction in waste materials. Due to the finest finishing, the processing time and cost are also reduced largely.
Conclusion
Medium-pressure die casting presents a great mixture of precision and efficiency in the casting world. You can perfectly craft your complex product designs through medium-pressure die casting as it provides the features in between high-pressure die casting and low-pressure die casting. Moreover, it is an eco-friendly, feasible, and cost-effective die-casting method.