Die Casting
We are one of Die Casting manufacturer and supplier in China. Here we will introduce more info about Die Castings,Such as types, alloy materials,applications.
What is Die Casting
Die Casting is a kind of pressure-casting part.It is a pressure-casting mechanical with a casting mold. The metal such as copper, zinc, aluminum or aluminum alloy heated to liquid is poured into the inlet of the die-casting machine. It is operated by forcing molten metal under high pressure into a die cavity.Casting copper, zinc, aluminum parts or aluminum alloy parts are often called die-cast parts. Die-casting parts have different names in different places. For example, die-casting parts, pressure castings, die-casting parts, die-casting aluminum, die-casting zinc parts, die-casting copper parts, copper die-casting parts, zinc die-casting parts, aluminum die-casting parts, aluminum die-casting parts, aluminum pressure Alloy castings, aluminum alloy die-cast parts, etc.
Generally speaking, die casting molds are firstly precision machined to net shape or near net shape of finished die cast parts.The die casting process usually produce parts using primarily non-ferrous metals. Such as zinc, copper, aluminum and magnesium. For steel and iron castings, investment casting and sand casting can be used.
Types of Die Casting
There are 2 different types of die casting process:Hot chamber die casting and cold chamber die casting. Hot chamber die casting mainly for: zinc alloy, magnesium alloy, etc.; Cold chamber die casting mainly for: zinc alloy, magnesium alloy, aluminum alloy, copper alloy, etc.
The key difference between the hot chamber and the cold chamber is whether the injection system of the die casting machine is immersed in the metal solution.
Hot chamber die casting
Hot chamber die casting is also called goose neck casting. It is one of the most popular of the main die casting processes. The Suitable metals for the hot-chamber die casting process include lead, magnesium, zinc, and copper,and other low melting alloys.
In hot chamber die casting,the cylinder chamber of the injection mechanism is completely immersed in the molten metal bath. As the cycle begins the piston will retracts. It allows the molten metal to fill the “goose neck” from a port in the injection cylinder. As the plunger move downwards, it seals the port and forces the molten metal through the goose neck and nozzle into the die. Once the metal solidifies, the plunger will pull upwards. Afterwards, the die will open and the part is ejected.Compared with cold-chamber process,This process lends itself to higher rates of part production. But the alloys for Hot chamber die casting need to be the materials of not attack the injection cylinder
Cold chamber die casting
The cold chamber die casting is very like hot-chamber die casting. But compared with the hot chamber die casting process,the disadvantage of the cold chamber die casting is relatively slower.
The cold chamber die casting’s design is focusing on reducing machine corrosion,not production efficiency. The melted metal is automatically- or hand-ladled into the injection system.This eliminates the necessity for the injection mechanism to be immersed in the molten metal bath.Cold Chamber Die Casting is the process primarily for manufacturing of aluminum die castings.For applications that are too corrosive for the immersion design of hot-chamber die casting, the cold-chamber process can be an excellent choice.
The benefits of the Die Casting
| High reliability: Uniformity of mass-produced parts is exceptional. |
| High quality: Parts created through die casting deliver a long service life. |
| Durability:Compared to plastic parts, die castings are stronger than their plastic counterparts. In most cases, even if thinner parts, die casting can still maintaining its strength for its application. Furthermore, die cast parts are able to withstand to a wide range of temperature, making it workable in harsh temperatures and working environments. |
| Quick production: Die cast tooling requires minimal maintenance.Due to the ability to produce complex parts in net shape with little or no machining processes required, it will greatly reduce the production time. So die casting is considered as one of the most effective process to mass produce non-ferrous metal complex parts. |
| Minimal assembly: Assembly features such as studs, drill holes, and bosses can be integrated into mold design. |
| Versatile design: Die casting can create virtually any size, part geometry, surface texture or luster. |
| Friendly Environment –Die casting parts are primarily made of recycled material. On average, approximately 95% of the metal is recycled from salvaged parts, making it a sustainable material that can be used over and over again without degradation. So die casting is a green manufacturing technique. |
| Thinner Wall Castings–Compared with sand casting or permanent mold castings, due to the high pressure during the injection process, die casting is able to produce parts with thinner wall thickness. This allows lightweight construction as well as eliminate or reduce the need of secondary operations |
| Casting with inserts–The die casting process allows inserts to be cast-in to form certain features such as threaded inserts, heating elements or high strength bearing surfaces. |
The main Alloys for Die Casting
1-Aluminum
| Aluminum is commonly employed in die-casting, but is prone to cracking or shrinking at high temperatures, so it is often alloyed with copper or silicon. Combining aluminum with these metals greatly increases its hardiness and fluidity. Since it has high dimensional stability, aluminum is used to create components with thin walls and complex shapes. Due to its corrosion resistance, aluminum is also beneficial in components that will face exposure to thermal or electrical energy. |
2-Copper
| Copper-based alloys are also commonly employed in die-casting. Many of these alloys are quite durable, making them an effective choice for mechanical products. Due to copper’s very high resistance to corrosion, it is often used to create plumbing and electrical material. |
3-Zinc
| Zinc die casting is a relatively easy process as it maintains high strength at room temperature, but can be alloyed with aluminum to further improve these qualities. Zinc has a lower melting point than aluminum and is suitable for hot-chamber casting. It is also valuable in the manufacture of products that require high precision and sturdiness, such as connectors and gears. |
4-Magnesium
| Magnesium has a high strength-to-weight ratio despite being a relatively light alloy, and it is useful for die-casting operations that require thin-structured walls and close precision. |
Die Casting Applications:
Most die castings are made from non-ferrous metals,such as aluminum, magnesium. It is most suitable for casting medium sized parts with complex shape. Die-casting is the largest casting technique that can be used to manufacture consumer, commercial and industrial products.Such as automobiles, toys, equipment, connector housing, gears, etc. Here is the most applications used for:
- Vehicles: Auto,bicycle parts
- Medical: surgical instruments,
- hospital equipment, hospital bed gearboxes and peristaltic pump pumps.
- Traffic lights:street and traffic light enclosures and aluminum light enclosures.
- Outdoor lighting: walk light housings, bullet light fixtures, coach lights and wall sconce fixtures.
- Industrial equipment: compressor and piston connecting rods, porter cable pump housings, wall mount bearing housings, industrial pumps, air compressors and many others.
- Telecommunications:electrical housings, connecting front face plates, waveguides, antenna mounts and RF filters.
Die casting company
We are one of China Die casting company and exporter.If you have any project on die casting.Contact us freely.