Low Pressure Casting

Low Pressure Casting

Low-pressure die casting (LPDC) is a process developed to improve the consistency and integrity of parts, at the cost of a much slower cycle time.In LPDC, material is held in a reservoir below the die, from which it flows into the cavity when air pressure in the reservoir is increased.Typical pressures range from 0.3 bar (4.4 psi) to 0.5 bar (7.3 psi).Somewhat higher pressures (up to 1 bar (15 psi)) may be applied after the material is in the die, to work it into fine details of the cavity and eliminate porosity.

Typical cycle times for a low-pressure die casting process are longer than for other die-casting processes; an engine  block can take up to fifteen minutes.It is primarily used for aluminum, but has been used for carbon steel as well.

Low Pressure Die Casting (LPDC) Process Advantages:

1. Improved Material Properties: LPDC allows for the use of high-strength alloys, resulting in stronger and more durable parts.

2. Reduced Porosity: The low-pressure process minimizes gas entrapment, reducing porosity and increasing part density.

3. Enhanced Surface Finish: LPDC produces a smooth, even surface finish, reducing the need for secondary machining.

4. Increased Dimensional Accuracy: The low-pressure process provides tighter tolerances and reduced shrinkage.

5. Reduced Scrap Rates: LPDC minimizes waste and scrap, resulting in cost savings.

6. Improved Casting Integrity: The process reduces the risk of casting defects, such as misruns and cold shuts.

7. Reduced Labor Costs: LPDC often requires less labor and handling compared to other casting methods.

8. Faster Production Rates: The process allows for quicker cycle times, increasing production efficiency.

9. Energy Efficiency: LPDC typically requires less energy compared to high-pressure die casting.

10. Design Flexibility: LPDC enables the creation of complex geometries and thin-walled parts.

Additional benefits:

- Reduced material waste

- Improved part consistency

- Enhanced mechanical properties

- Ability to cast large and complex parts

Overall, Low Pressure Die Casting offers numerous advantages, making it a popular choice for producing high-quality, complex parts in various industries, including automotive, aerospace, and more.