The traditional die‑casting process employed by die‑casting manufacturers typically comprises four key steps: high‑pressure die casting. These steps include mold preparation, filling, injection, and shakeout, and they form the foundation for various advanced die‑casting techniques. Before commencing the process, die‑casting manufacturers apply a lubricant to the mold cavity. In addition to helping regulate mold temperature, the lubricant also facilitates the release of the cast part from the mold. The mold is then closed, and molten metal is injected into the cavity under high pressure.

Die‑casting manufacturers typically operate within a pressure range of approximately 10 to 175 MPa. After the molten metal has been injected into the mold, pressure is maintained until the casting solidifies. A ejector pin then removes all the castings. Since a single mold may contain multiple cavities, several castings can be produced in each cycle. The shakeout process involves separating residual material, including sprues, runners, gates, and flash. Die‑casting shops commonly perform this step by using specialized trimming dies to squeeze the castings free. Other shakeout methods include sawing and grinding. If the gates are brittle, the castings can be shot‑blasted directly, which reduces labor costs. Excess sprue material can be remelted and reused. Typical yield rates are around 67%.

High-pressure injection in die‑casting allows for extremely rapid mold filling, enabling the molten metal to completely fill the cavity before any part of the casting solidifies. This approach helps prevent surface defects even in thin‑walled components that are difficult to fill. However, it can also lead to air entrapment, as air is challenging to vent during fast mold filling. This issue can be mitigated by incorporating venting holes along the parting line; nonetheless, even highly precise processes may still leave a porosity defect at the center of the casting. Most die‑cast parts can be further finished through secondary operations—such as drilling and polishing—to achieve features that cannot be produced directly during the casting process.

After shakeout, defects can be inspected. Common defects include misruns (unsatisfactory casting). These may result from inadequate mold design or insufficient molten metal temperature on the part of the die‑casting manufacturer, as well as from metal–impurity contamination, insufficient venting, and excessive lubricant. Other defects include porosity, shrinkage, hot tearing, and flow marks. Flow marks are surface imperfections caused by gate defects, sharp corners, or excess lubricant.

Low-pressure castings feature a dense microstructure, excellent gas tightness, stable dimensional accuracy, and reduced machining requirements, making them well suited for a wide range of sealed, pressure‑bearing components. We offer custom mold development based on your drawings or samples, can tailor the casting process to meet specific operating conditions, and are capable of producing non‑standard, complex‑shaped parts and special‑specification castings to your exact specifications.