This work describes the origin, procedure, and advantages of Die casting. It is a metal casting technique in which one pushes molten metal under high pressure into a mold cavity. Along with presenting the general facts on the subject, the writer goes into detail, explaining the operation of die casting machines, the process of making dies, and some quick tips to help the manufacturers improve efficiency. In addition, the book contains a chapter dedicated to the die casting company E. B. Van Wagner Mfg. Co., illustrating how their operations are carried out. Contents include: Die Casting Making Dies for Die-Casting Machines Van Wagner Mfg. Co.'s Die-Casting Practice

"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

In the current study, an industrial product (electrical wire connector) have been casted in cold chamber die casting process using LM2 aluminium alloy to produce certain specimens to be assessed under the study for the determination of the responses ( mechanical properties such as impact strength, hardness and surface roughness). As cold chamber die casting is being popularly known for its efficient and accurate casting process which can process a broad range of castings with intricate shape easily, hence it requires a lot of study in controlling the process variables with optimum combination of process variables to produce defect free and sound casting. Therefore in the current study, the process variables such as pouring temperature (725oC, 750oC, 775oC), intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2), type of coating (oil+graphite coating, dycote+graphite coating and dycote coating) and type of cooling (air cooling, water cooling and oil cooling) have been varied at three levels and 9 different experiments have been designed using Taguchi array (L9 orthogonal array) to assess the effects of different combinations of process variables over the mechanical properties (impact strength, hardness and surface roughness). The study aims at selecting the optimum combination process variables on the basis of the responses resulted in the 9 experiments. The graphs for the responses (impact strength, hardness and surface roughness) against each process variables have been plotted and carefully observed to identify the significant process variable along with respective level of operation affecting the respective response. From the overall study, intensification pressure was concluded to be the most significant process variable with maximum contribution to the impact strength and surface finish. The micrograph images captured corresponding to the respective levels of intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2) revealed the presence of shrinkage porosity corresponding to lowest level of intensification pressure (170 kg/cm2) and with further increase in intensification pressure led to a decrease in the extent of presence of porosity. Dycote coating was considered as the most optimum coating with significant contribution to the hardness. Air cooling and oil cooling were equally significant process variables with equivalent contribution to the mechanical properties.