Week 11: Mass Production 2 (30 Flashcards)

What is die casting?

A process of injecting molten metal into a steel mold under high pressure.

What are the two main types of die casting?

Cold chamber and hot chamber.

What metals are used in hot chamber die casting?

Low-melting-point metals like zinc.

Why is cold chamber die casting used for aluminum?

Aluminum’s high melting point requires an unheated chamber to prevent tool damage.

What is the purpose of ejector pins in die casting?

To push the molded part out of the mold after solidification.

What is a sprue in die casting?

The entry point for molten metal into the mold.

What is the role of runners in molds?

Channels that distribute molten metal to various parts of the mold.

Why are sliders used in die casting molds?

To create undercuts or complex geometries.

What is the Giga Press?

A massive die casting machine used by Tesla for large parts.

How does draft angle affect die casting?

Ensures parts can be ejected without damaging the mold.

Name three metals commonly used in die casting.

Zinc, aluminum, magnesium.

What is powder coating?

A durable, eco-friendly coating applied as a powder and cured with heat.

What are the benefits of powder coating?

Scratch resistance, VOC-free, variety of finishes.

What is PVD coating?

Physical vapor deposition creates thin, durable layers on parts.

What is anodizing used for?

Improving aluminum’s corrosion resistance and surface finish.

Why is porosity a concern in die casting?

It weakens parts and can lead to functional failures.

What is vacuum impregnation?

A process to seal porosity in cast parts, making them watertight.

What are the advantages of using zinc in die casting?

Low melting point, durability, corrosion resistance.

Why is aluminum used in automotive applications?

Lightweight, strong, good thermal properties.

How does magnesium compare to aluminum in die casting?

Magnesium is lighter but offers lower strength.

What are the key steps in the die casting process?

Molten metal injection, cooling, ejection, trimming.

Why is surface finishing important?

Improves aesthetics, corrosion resistance, and durability.

What is the function of gates in die casting molds?

Control metal flow into the mold cavities.

How are ejector pin marks managed?

By specifying placement in the design process.

What are the benefits of clearcoats in automotive painting?

Protects paint layers and controls gloss levels.

Name three materials used for powder coating.

Epoxy, polyester, urethane.

What is deep drawing?

Shaping sheet metal by drawing it into a die using a punch.

What is the main use of stamping in manufacturing?

Producing automotive body parts.

What is spinning, and where is it applied?

Forming metal using a lathe; used for round, complex shapes like cookware.

What is slide forming?

A process for creating small, intricate metal parts using a series of punches.