The traditional die casting process is mainly composed of four steps, or called High Pressure Aluminum Die Casting. These four steps include mold preparation, filling, injection, and sand falling, which are also the basis for various improved die casting processes. During the preparation process, a lubricant needs to be sprayed into the mold cavity. In addition to helping to control the temperature of the mold, the lubricant can also help demold the casting. Then you can close the mold and inject the molten metal into the mold with high pressure. The pressure range is about 10 to 175 MPa. When the molten metal is filled, the pressure will be maintained until the casting is solidified, and then the push rod will push out all the castings.

Since there may be multiple cavities in a mold, multiple castings may be produced during each High Pressure Aluminum Die Casting. The doffing process requires the separation of residues, including mold openings, runners, gates and flash. This process is usually done by extruding the casting with a special trimming die. Other methods of doffing include sawing and sanding. If the gate is fragile, the casting can be directly beaten, which can save manpower. The excess mold opening can be reused after melting. The usual yield is about 67%.

High Pressure Aluminum Die Casting injection results in a very fast filling of the mold, so that the molten metal can fill the entire mold before any part solidifies. In this way, even thin-walled parts that are difficult to fill can avoid surface discontinuities. However, this can also lead to air entrapment because it is difficult for air to escape when the mold is filled quickly. This problem can be reduced by placing an exhaust port on the parting line, but even a very precise process will leave pores in the center of the High Pressure Aluminum Die Casting. Most die-casting can be completed by secondary processing to complete some structures that cannot be completed by casting, such as drilling and polishing.