Extrusion

Extrusion is the process by which long straight metal parts can be produced. The cross-sections that can be produced vary from solid round, rectangular, to L shapes, T shapes. Tubes and many other different types. Extrusion is done by squeezing metal in a closed cavity through a tool, known as a die using either a mechanical or hydraulic press.
Extrusion produces compressive and shear forces in the stock. No tensile is produced, which makes high deformation possible without tearing the metal. The cavity in which the raw material is contained is lined with a wear resistant material. This can withstand the high radial loads that are created when the material is pushed the die.
Extrusions, often minimize the need for secondary machining, but are not of the same dimensional accuracy or surface finish as machined parts. Surface finish for steel is 3 µm; (125 µ in), and Aluminum and Magnesium is 0.8 µm (30 µ in). However, this process can produce a wide variety of cross-sections that are hard to produce cost-effectively using other methods. Minimum thickness of steel is about 3 mm (0.120 in), whereas Aluminum and Magnesium is about 1mm (0.040 in). Minimum cross sections are 250 mm² (0.4 in²) for steel and less than that for Aluminum and Magnesium. Minimum corner and fillet radii are 0.4 mm (0.015 in) for Aluminum and Magnesium, and for steel, the minimum corner radius is 0.8mm(0.030 in) and 4 mm (0.120 in) fillet radius.

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Hot Die Casting

Hot chamber die casting is one of the two main techniques in the manufacturing process of die casting. This section will primarily discuss the specific details of the hot chamber process and contrast the differences between hot chamber die casting and cold chamber die casting, which is the other branch of die casting manufacture.

Hot Chamber Process

A similar characteristic of either die casting process is the use of high pressure to force molten metal through a mold called a die. Many of the superior qualities of castings manufactured by die casting, (such as great surface detail), can be attributed to the use of pressure to ensure the flow of metal through the die. In hot chamber die casting manufacture, the supply of molten metal is attached to the die casting machine and is an integral part of the casting apparatus for this manufacturing operation.




The shot cylinder provides the power for the injection stroke. It is located above the supply of molten metal. The plunger rod goes from the shot cylinder down to the plunger, which is in contact with the molten material. At the start of a casting cycle, the plunger is at the top of a chamber (the hot-chamber). Intake ports allow this chamber to fill with liquid metal.
As the cycle begins, the power cylinder forces the plunger downward. The plunger travels past the ports, cutting off the flow of liquid metal to the hot chamber. Now there should be the correct amount of molten material in the chamber for the "shot" that will be used to fill the mold and produce the casting.

At this point the plunger travels further downward, forcing the molten metal into the die. The pressure exerted on the liquid metal to fill the die in hot chamber die casting manufacture usually varies from about 700psi to 5000psi (5MPa to 35 MPa). The pressure is held long enough for the casting to solidify.

In preparation for the next cycle of casting manufacture, the plunger travels back upward in the hot chamber exposing the intake ports again and allowing the chamber to refill with molten material.

For more extensive details on the setup of the mold, the die casting process, or the properties and considerations of manufacturing by die casting see die casting for the basics of the process.
Hot chamber die casting has the advantage of a very high rate of productivity. During industrial manufacture by this process one of the disadvantages is that the setup requires that critical parts of the mechanical apparatus, (such as the plunger), must be continuously submersed in molten material. Continuous submersion in a high enough temperature material will cause thermal related damage to these components rendering them inoperative. For this reason, usually only lower melting point alloys of lead, tin, and zinc are used to manufacture metal castings with the hot chamber die casting process