Die-casting and Precision Machining

1.1 ORIGINS OF HIGH PRESSURE DIE CASTING
Casting processes are among the oldest methods for manufacturing
metal goods. In most early casting processes (many of which
are still used today), the mold or form used must be destroyed in
order to remove the product after solidification. The need for a
permanent mold, which could be used to produce components in
endless quantities, was the obvious alternative.al die casting
In the Middle Ages, craftsmen perfected the use of iron molds
in the machining Components of pewterware. Moreover, the first information
revolution occurred when Johannes Gutenberg developed a
method to manufacture movable type in mass quantities using a
permanent metal mold. Over the centuries, the permanent metal
mold processes continued to evolve. In the late 19th century processes
were developed in which metal was injected into metal dies
under pressure to manufacture print type. These developments culminated
in the creation of the linotype machine by Ottmar Mergenthaler.
However, the use of these casting methods could be
applied to manufacture more than type for the printing press.
H. H. Doehler is credited with developing die casting for the
production of metal components in high volumes. Shown in Figure
1.1 are diagrams filed with patent 973,483 for his first production
die casting machine.1 Initially, only zinc die casting alloys were used
in die casting . Demands for other metals drove the developmentof new die materials and process variants. By 1915, aluminum die casting
alloys were being die cast in large quantities.2 zinc die casting
Much progress has been made in the development of die casting
technologies over the last century. Developments continue to be
made driving the capabilities of the process to new levels and
increasing the integrity of die cast components.