Why would a product designer choose a die casting over a component manufactured by another competing process?
What are the capabilities of a product made with the die casting?
During this session, we will answer those questions. We will also explore the length and breadth of die casting applications, and explain the unique characteristics and optimum die casting configuration.
After completing this chapter, you will be able to:
List the advantages of using die casting process
Identify die casting
The large aluminum automotive transmission housing shown on the above is produced on a 3500 ton cold chamber die casting machine. The aluminum fills the complex die cavity in less than ½ second and a completely formed solidified casting is ejected from the die every two minutes. Transmission housings weigh up to 35 lb. In contrast, the small zinc line connector for a cook stove is produced on a much smaller machine. The zinc fills the cavity on the order of a few hundredths of a second and several castings are ejected every minute. The weight of each of these castings is 0.5 ounces.
List the characteristics of the optimum die casting configure
Identify the components of the die casting shot
The information presented in this chapter is of general interest and is background information for material presented in following chapters.
In the previous information you learned general information about the die casting industry in China. In this chapter you will learn specific information about the die casting.
The following new terms are used in this chapter.
Diecasting“shot”Defined as a noun in this chapter, not a verb.
SprueCone-shaped metal part of the shot that connects the nozzle and runner.
OverflowsSmall pockets of metal around the perimeter of the part and also in openings.
RunnerThe path the metal must flow through to get from the sprue or biscuit to the casting.
TheDieCastingAdvantage
Die casting produces components at high speed from a range of durable zinc, magnesium , and aluminum alloys while faithfully capturing the most intricate design details.
This capability makes it a prime production option for high volume production components. The ability to maintain close tolerances, often eliminating all machining, can make the process the optimum choice for lower-volume production as well.
Modern process technology that insures consistent quality
Computer control of the significant process variables has led to consistent dimensional control and internal integrity. The process responds to statistical control and statistical problem solving techniques.
Freedom to design intricate configurations
Design configuration is only limited to the designer’s imagination and the mold maker’s ingenuity to build the casting die. A typical example of an intricate configuration is the automotive transmission valve body.
Net-shape casting economies, even at lower volumes
Elimination of machining and secondary operations can make die casting competitive at low production volumes.
Wide variety of available alloys and alloy properties
Recall that the typical metals are alloys of aluminum, magnesium and zinc. Small volumes of alloys made from copper and lead are also routinely die cast. Iron and titanium materials have also been die cast. Current alloy development includes the use of composite materials, aluminum and silicon carbide for example.
The rigidity, look and feel of metal
The perceived quality of a metal component is higher than that made from a non-metallic material. Rigidity is analogous to strength, and is based on the modulus of elasticity, and configuration. Good rigidity also reduces vibration.
Meets moderate to high strength performance
Die cast alloy strengths are above plastics and slightly below those of sheet steels.
Moderate to high impact and dent resistance
Selected alloys have very high-energy absorption capability.
Documented fatigue strength characteristics
Published values of fatigue strength are conservative. High density casting processes minimize defects, such as porosity, that initiate fatigue.
Excellent sound damping properties
Studies indicate zinc and ZA alloys are good at sound damping. Magnesium has demonstrated sound damping in drive train components.
Bearing properties that often eliminate separate bearings
ZA alloys have good bearing properties. Aluminum 390 alloy shows good wear resistance.
Inherent EMI shielding for electronic applications
High conductivity provides inherent shielding
Pressure tightness for hydraulic and pneumatic components
Alloy selection, gating technology and vacuum systems greatly reduce trapped gases and shrinkage porosity.
High quality surface finishes for decorative applications
Good surface finish is relatively easy to achieve. A variety of surface treatments are easy to apply.
Meets criteria for serviceability and recyclability
Alloys are “green”, easily recycled. The aluminum alloys are usually produced from recycled materials. The die casting alloy recycling stream is based on a worldwide metal reclamation infrastructure that has been operative for more than 50 years.
Today, with the introduction of new, higher performing die casting alloys and new process technologies, many of the old design assumptions about process limitations have become obsolete.
New specifications for dimensional control, draft and flatness have been issued. These specifications are reviewed and updated on a periodic basis.
New process enhancements including vacuum technology, squeeze casting, semi-solid casting and thixotropic molding have been developed and have led to significantly reduced levels of porosity.
The Optimum Die Casting Configuration
Before a die casting project is undertaken, the casting design should be evaluated in terms of manufacturability. In other words, can the casting be manufactured? Is the casting design optimum?
The optimum die casting configuration will:
Fill completely with metal.
Solidify quickly without defects.
Eject readily from the die.
The optimum casting configuration does not just happen.
Engineers and designers must work together to make sure the casting design fulfills the product requirements and can be manufactured. To achieve both of these goals, the die casting must be designed with features that capitalize on the characteristics of the die casting process. The following six principles should be used in working toward and developing the optimum die casting configuration.
Aluminum die casting items are of remarkable use in different industry sectors and more so in the aerospace engineering where precision and top standard items is of greatest significance. These items are used in building both little as well as the big components in the aviation industry. Additional, die casting aluminum are used both in the pivotal military sector as well as commercial. The reason for this is easy – they are cost-friendly solutions and provide amazing outcomes.
Apart from being cost effect, the parts made from die casting aluminum are additionally prepared to endure extreme weather situations and increased damages. Another vital reason for using aluminum products in aircraft is that the meal is comparatively affordable than other metals that are die casted. Additional, aluminum has the potential to get with other metals in order to provide durability and much flexible.
With aluminum casted products, you do not have to compromise on the standard yet can them at much affordable production cost. Further, all the standards that have been set for using of metal components, aluminum relax the need to the utmost. Hence, they are certified secure for use in planes, affordable and have all the qualities that are needed for flying crafts. So casting aluminum is on the boost like never before. Further, the top thing about an aluminum die cast part is that its weight is favorable for the aircraft works.
So, how actually is casting Aluminum done and what are the processes involved? Well, the reply is simple. Aluminum alloy is first forced into a top-grade steel at high speed and force in a high temperature. This outcomes in superior standard products that are very light and thin walled perfect for use as aircraft components.
It is to be mentioned here that Aluminum diet casting is a hard technique. Only a truly experienced and top standard team of engineers can make sure that the parts come with top volumes or with excellent tolerances and surface finish. Actually, this type of force casting is far more famous than gravity die casting or sand casting. This is because the need for machining is this type weather for Zinc or aluminum casting is extremely low due to the close casting tolerances. Though the tooling cost in casting Aluminum or rather any metal are considerably higher than the other 2 types yet, the mechanical properties achieved thus are far excellent in terms of functionality.
https://www.thediecasting.com/wp-content/uploads/2019/10/Aluminum-Aerospace-parts-.jpg250333adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2019-10-17 20:12:232019-10-12 20:21:56Aluminum die casting and its importance in Aerospace Industry
Die casting is a metal casting process which is characterized by pressing molten metal into the mold cavity. The mold cavity is made using two hardened tool steel molds that are worked on during processing and work similarly to injection molds. Most die-casting is made from non-ferrous metals, especially zinc, copper, aluminum, magnesium, tin, lead, and tin-based alloys. Depending on the type of metal being thrown, a thermal or cold engine is used.
Zinc die casting
The zinc die casting process is very popular for making parts in building and industrial fields, but the most common application is in the automotive industry. In fact, cars have different parts that can be made through die casting, in such a way that the modern process of die casting was originally started for the automotive industry.
With the casting process often no further machining is needed after casting: not only is the accuracy up to 99.8%, but the casted products can also be used raw because they have a pleasant finish. The use of zinc die casting is almost 28% in the automotive industry, followed by the building and hardware sector.
Zinc has become one of the most important metals in the auto parts industry, especially for products such as door lock housing, pawl, gears and retractor pulleys in seat belt systems, but also for camshaft and sensor components. By using this metal and its alloys, it is possible to achieve strength, ductility, and flexibility that would not be possible with other materials.
In addition, zinc can be the right choice to get high-quality aesthetic components, with tight tolerances that are not possible with other materials, and to get embossing and grooves for mechanical components or gears.
Zinc Die Casting Mechanisms in Automotive
As said before, the automotive industry is the most common die casting application: using zinc and its alloys makes it possible to produce components that are able to achieve high aesthetic quality, with tight and narrow tolerance for shape morphology. Zinc alloys are also used for coatings because of its many benefits, such as improving the anti-corrosion properties of zinc which are already impressive.
Below you can find a number of possible examples of zinc plating:
Interior aesthetic section
Sunroofs Section
Mechanical parts
Engine and other underhood components
Power steering system
Parts and brake system
Air conditioning components and systems
Chassis hardware
Parts in the seat belt system
Components of climate control
Fuel system
Advantages for Zinc Die Casting:
An efficient & economical process offering various forms & forms possible.
High-Speed Production
Dimension Accuracy & Stability
Strength & weight
Several finishing techniques are available
Simple Assembly
The Die Casting process began with the use of lead and lead alloys, magnesium and copper alloys which were quickly followed, and in the 1930s, many modern alloys still in use today are available. This process evolved from casting low-pressure injection to modern high-pressure injection of 4,500 pounds per square inch. The modern process is capable of producing high integrity, clean casting forms with excellent surface finishes.
Zinc casting alloy is a strong, durable and cost-effective engineering material. Their mechanical properties are competitive and are usually higher than cast aluminum, magnesium, bronze, plastic and most cast iron.
https://www.thediecasting.com/wp-content/uploads/2019/09/Zinc-die-casting.jpg250305adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2019-09-28 14:25:252019-09-20 14:42:18The importance of zinc die casting in the automotive industry
The process of die casting with pressure injection can be followed until mid-1800. The components used were tin and lead, but the use has disappeared with the introduction of zinc and Aluminium alloys. This process has evolved over the years, from low-pressure injection molds to casting molds at pressures of up to 4,500 psi. The process can create high-quality products with excellent end surfaces.
Die Casting is an economical and efficient process for making various shapes. Considered superior to other manufacturing techniques, it is durable and aesthetic and combines perfectly with other parts of the machine that are part thereof. Dying has many advantages. Among these, the main is its ability to produce complex forms with a higher tolerance level than other mass-production methods. Thousands of identical prints can be produced before you need to add new mold tools.
Zinc die casting
High Die-pressure is a manufacturing process where aluminum that has been melted is injected by a casting machine under extreme pressure on steel or molds to make the design and detail parts of the model you want to make. Casting in tons of universal tightening. This record reflects the amount of pressure given on the matrix. The engine size varies from 400 to 4000 tons.
There are many advantages to using the die casting process compared to others. Die casting produces parts with thinner walls, narrower size limits and processes can be accelerated. Labor costs and finishing are the lowest with the dice. This process facilitates to obtain intricate forms with narrower tolerances. Unlike the forgery process, you can insert the kernel into the product created by this process.
Forms that cannot be obtained from rods or tubes can be easily achieved with casting. The number of operational processes is smaller, which leads to the reduction of waste materials.
Die casting is used when you need a stable, dimensional and durable component. They withstand heat and maintain a good level of tolerance, an important condition for each part of a good machine. They are stronger and lighter than the part made by other printing methods. Its parts are not welded or screwed, which greatly increases its efficiency. Another advantage is the many workarounds that you can get with the launch. Surfaces can be smooth or textured, which facilitates the application and its use.
Hopefully, this information can help you and thank you for reading the article about Zinc Die casting.
https://www.thediecasting.com/wp-content/uploads/2019/09/Zinc-die-casting.jpg250305adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2019-09-14 10:19:392019-09-14 10:19:39Favorable Manufacturing For Zinc Die Casting Processes
Capacity To Meet Your Aluminum, Magnesium, Zinc and Vacuum Die Casting Needs.
Aluminum Die Casting
Providing high-quality Aluminum die casting parts at competitive prices requires modem die casting equipment. To reduce the effects that extreme cooling temperatures have on dies CNM TECH is converting its die cooling system from water to oil. Oil maintains a warmer die temperature that contributes to a more uniform casting and extends die life, an important factor in part costs.
CNM TECH Die Casting company is adapting robotic controls to the operation of die casting machines. This permits a substantial increase in production rates, important in both controlling costs and meeting delivery requirements. It also allows us to use our people in ways which make better use of their skills and experience.
To lower production costs, CNM TECH Die Casting manufacturer has developed and patented, new, low volume, energy efficient aluminum melting furnaces. Since aluminum can be melted efficiently in small quantities, it allows the company to supply casting machines with different alloys of aluminum simultaneously. Casting machines don’t have to stand to wait for a large furnace to supply the proper alloy. Schedules aren’t built around what alloy is in the furnace.
Zinc Die Casting
For applications where high impact strength, low cost and close dimensional limits are important design considerations, zinc die casting plays an important role. Zinc normally permits higher production rates than aluminum and parts can be designed with thinner cross-sections. The resulting parts are highly resistant to corrosion and receptive to a variety of beautiful finishes.
High rates of production and uniform quality are maintained by die casting machines with automatic extractors.
Vacuum Die Casting
Vacuum die casting is preferred by many casting buyers because it results in a less porous part. CNM TECH’s Vert-a-Cast machines, with a clamping force of 400 tons, are capable of producing castings automatically at a much faster pace than manually-operated horizontal machines.
Vacuum die casting, a CNM TECH capability for ten years, is often the only economical way to meet critical porosity specifications.
Maintenance, repair, changes and corrections on dies are accomplished promptly in CNM TECH’s fully-equipped tool and die shop.
Alloy materials are melted, fluxed and cleaned in the central furnace before being transferred to die casting equipment.
If you have any die casting requirement, you are welcome to send us your requirement for a quotation.
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CNM Die Casting is your one-stop, complete service Die Caster for various die casting parts including aluminum die casting, investment casting, sand casting. We offer you a single source for engineered die castings, together with cutting-edge engineering resources, advanced production capabilities and complete secondary finishing.
CNM Die Casting supplies high-quality aluminum, zinc, brass and magnesium die castings. We operate our casting factory in DongGuan, China for various castings, machining, assembly and die building, with over 20,000 square feet of total floor space.
We are a leader in innovative quality control systems. Our quality manufacturing system includes a process failure detection system
at every casting press. Rigorous 100% inspection is as much a production operation as any other manufacturing step and is woven into the sequential standardized work to assure manufacturing quality in finishing and machining.
As one of the divisions of CNM Manufacturing Group, CNM Die Casting can be more responsive to its customers and, simultaneously, offer more competitive, “made in China” pricing on quality products.
CNM Die Casting’s tooling department builds dies with state-of-the-art equipment.
Along with our experienced engineering and tooling department, we design tooling and assist customers with casting design issues. Excellent control of design and tool building allows us to produce high quality tools and parts at lower cost, and more quickly than anyone else in the industry.
Our Engineering and Tooling Department offers:
Tool Engineers to ensure specifications and dimensional criteria are met to the customer’s requirements
Design Engineers with the latest CAD/CAM technologies to design both product and tooling for the customer’s specification.
Technical on-site product design assistance for die castings
Production tooling built with CNC machines by in-house full capability large tooling facility state-of-the-art
EDM machines rapidly burn cavities to near-finished condition with oscillating feed.
Prototyping in the same tooling intended for production
Production tools are built with premium grade materials
Metal casting services involve the shaping of free-flowing liquid metals through the use of dies, molds, or patterns. Castings are generally roughly finished due to the nature of their production. In many cases, additional finishing is required to remove burrs and other artefacts of the casting process. Metal castings services are used to design a wide range of components and finished products. Everything from simple nails and fasteners to engine blocks can be fabricated using metal casting services. Common metal casting processes include sand casting, die casting, permanent mold casting, investment casting, centrifugal casting, and lost foam casting.
Sand casting is used to make large parts (typically iron, but also bronze, brass, aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or synthetic). Sand castings generally have a rough surface, sometimes with surface impurities and surface variations.
zinc Die Casting
Die-casting includes a number of processes in which reusable dies or molds are used to produce casting. The die contains an impression of the finished product together with it’s running, feeding and venting systems. The die is capable of a regular cycle and of (quickly) dissipating the heat of the metal poured into it. Once the liquid metal has cooled sufficiently, the mold is opened and the casting can be removed and finished.
In permanent mold casting, molten metal is poured into cast iron molds, coated with a ceramic mold wash. Cores can be a metal, sand, sand shell, or other materials. When completed, the molds are opened and the castings are ejected.
Investment casting services involve molding patterns by the injection of a special wax into a metal die. The patterns are assembled into a cluster around a wax runner system. The ‘tree’ of patterns is then coated with 8-10 layers of refractory material. The assembly is heated to remove the wax. The hot mold is cast, and when cool, the mold material is removed by impact, vibration, grit blasting, high-pressure water blasting or chemical dissolution leaving the castings, which are then removed from the runner system.
Centrifugal casting
Centrifugal casting services are used to produce castings that are cylindrical in shape. In centrifugal casting, a permanent mold is rotated about its axis at high speeds as the molten metal is poured. The molten metal is centrifugally thrown towards the inside mold wall, where it solidifies. The casting is usually a fine grain casting with a very fine-grained outer diameter, which is resistant to atmospheric corrosion, a typical need with pipes. The inside diameter has more impurities and inclusions, which can be machined away.
magnesium die casting
Lost foam casting
Lost foam casting (LFC) is metal casting services that use foam filled patterns to produce castings. Foam is injected into a pattern, filling all areas, leaving no cavities. When molten metal is injected into the pattern, the foam is burned off allowing the casting to take shape.
Die casting
Die casting and metal casting includes a number of processes in which reusable dies or molds are used to produce casting. The die is capable of a regular cycle and of (quickly) dissipating the heat of the metal poured into it. Once the liquid metal has cooled sufficiently, the mold or is opened and the casting can be removed and finished.
In the die casting process, molten metal is injected under pressure into a reusable mold or die. The die contains an impression of the casting together with it’s running, feeding and venting systems. The die is capable of a regular cycle and of (quickly) dissipating the heat of the metal poured into them. Once the liquid metal has cooled sufficiently, the mold or is opened and the metal casting can be removed and finished.
The high pressure die casting process is the most widely used, representing about 50% of all light alloy casting production. Low pressure die casting currently accounts for about 20% of production and its use is increasing. Gravity die casting accounts for the rest, with the exception of a small but growing contribution from the recently introduced vacuum die casting and squeeze casting process. the design of low pressure and gravity die casting dies for improved die filling, optimized solidification pattern and maximum yield. Gravity die-casting is suitable for mass production and for fully mechanized casting. Low-pressure die casting is especially suited to
Aluminum Die Casting
the production of components that are symmetric about an axis of rotation. Light automotive wheels are normally manufactured by this technique.
Die casting metals can vary widely, and different die casting companies may have the ability to work with anyone or number of them. Some of the most common metal casting types include aluminum die casting, brass die casting, lead die casting (the most popular for model die casting), magnesium die casting, and zinc die casting.
Hope all of that information is enough for your reference, but if you want to know more information, you are welcome to contact us by phone or email.
Metal casting is highly crucial in modern manufacturing. It is technically shaping the whole world. As you know, you can create a wide range of metal parts from this method. High Pressure Die Casting is one of the most popular metal casting methods here.
A typical metal casting method pours molten metal into a mold to create complex and precise shapes. Every industry needs these casting parts for many applications. They may need them for structural support or in their main products.
One popular way to shape metal is through die-casting, and high pressure die casting is one of the most common die-casting methods. This method is what this article is mostly about. You will learn about how they are made, their benefits, and how they can be used. You will also find out how HPDC and LPDC are different.
Overview of High Pressure Die Casting (HPDC)
HPDC stands for High-Pressure Die Casting. As the name suggests, this metal casting method needs high pressure. HPDC casting is suitable for making many metal parts with high tolerances.
In HPDC die casting, molten metal is injected into a steel mold or die at high speeds and pressure. As a result, you can create hundreds of casting parts in less time. The pressure needed here is to ensure that the molten metal fills the detailed feature of the die. Because of this, high-pressure die casting is suitable for high-volume production.
An high pressure die casting machine is made up of several primary components. All of them are very important to the system. You might also find other parts, though. However, these four parts are the most important things in high pressure die casting process. They usually decide how good the casting parts are in the end.
Die Cast Molds
Die-cast molds, or dies, are high pressure die casting machine parts that generally determine the final shape. They have two main halves: stationery and movable. They are usually made from high-strength steel. Making these HPDC die-cast molds is called high pressure die casting tooling. Note that HPDC tooling is crucial for the best quality of metal casting.
Ejector Pins
Ejector Pins are another important components in high pressure die casting mold. They facilitate the removal of the solidified cast from the die. You can find these pins within the movable die half. Once your metal casting is cooled and solidified, you can actuate these pins to remove it. It mainly plays a crucial role in the production cycle.
Cold chamber die casting machine
Cold chamber die casting machine is a most important machinie which has injection system, press system, ejection systems and so on. all of die casting process will be done by this cold chamber die casting machine.
Heating Components
Heating components may include furnaces and heating elements. They typically do not melt the metal but keep the temperature constant. The main goal of this high pressure die casting machine part is to ensure the metal is in liquid form. Note that consistent heating is crucial for the quality and consistency of the final castings.
How DoesHigh Pressure Die Casting Work?
Generally, high pressure die casting works in five steps. Each step is crucial for the final quality of the castings. Therefore, when starting a die-casting process, always inspect the device. Check for any defects or loose screws. Always tune your device to its optimal settings. Check whether the cooling system is properly working or not.
Once you have checked your device correctly, you can proceed to the primary high pressure die casting process. Always wear safety gear, such as gloves, clothes, and glasses.
Step #1 Preparing the Die Cast Mold
You can prepare the high pressure die casting mold in two main steps. First, if it has already been made, check it for defects and contamination before using it. Second, designing the mold is necessary for customized products.
Designing a die-cast mold has several stages. First, you can draw your design using 3D software like SolidWorks, AutoCAD, and more. Ensure you have properly organized the gate runner and mold base when designing it. The cooling system is also a crucial part of this design process. Finally, check the venting & ejection system.
Once you are done with the design, proceed with the draft analysis. You can check its functionality on various simulation software. After testing and quality inspection, you can use the die casting tooling for your final production.
Step #2 Molten Metal Injection
In this HPDC casting process, the machine injects molten metal into the die cavity. Unlike other methods, high-pressure casting uses high pressure and speed for this job, which is why it is called high-pressure die casting.
First, tightly connect the two halves of the die-casting mold. Then, with a button push, the HPDC machine forces the molten metal into the chamber. This pressure technically ensures that the molten metal fills the entire cavity. Once the injection is done, the molten metal is allowed to cool and solidify.
Two primary injection methods are used in the HPDC die-casting system. You can choose the correct method for the job based on your project needs.
Hot Chamber Injection
When your injection mechanism is immersed in the molten metal reservoir, it is called hot chamber injection. When the plunger moves, it draws the molten metal into the chamber and injects it into the die cavity. This type of injection is suitable for metals with low melting points. You may often find this hot chamber die casting machine is used zinc and magnesium alloys.
Cold Chamber Injection
Cold chamber injection, on the other hand, uses a separate melting furnace. You can pour the molten metal using a manual or automated system. In manufacturing, the automatic system is generally operated by a hydraulic plunger. It forces the molten metal to insert into the mold cavity. Cold chamber injection is a common technique for aluminum HPDC casting.
Step #3 Cooling & Solidification
After injection, the molten metal quickly cools within the die cavity. Some factories, like CNM TECH, use controlled cooling. During this time, you must ensure proper solidification.
Note that adequate cooling is mainly necessary to avoid defects. As you know, several defects occur due to inappropriate cooling. Some defects are hot spots, cold shuts or misruns, shrinkage, and porosity.
Cooling channels within the die typically stabilize the temperature. You must ensure these cavities are correctly designed when designing a die-cast mold. At CNM high pressure die casting Factory, our experienced engineers always test these cooling systems. Thus, our metal casting has almost zero defects.
Step #4 Ejection
Once the metal alloy part has cooled and solidified within the die, eject it using the ejector pins. Carefully do this step to avoid any external damage. The ejector pins usually facilitate this removal process. They are on the movable part of the die-cast mold.
Step #5 Trimming & Finishing
After removing the metal part, you may find some extra material on the body. You may need some additional finishing processes to get it in good shape. You can perform trimming, grinding, or other surface treatment methods.
The trimming method usually removes excess material from the metal part. It can be manual or automated. However, a smooth surface may need grinding, sanding, or machining. These methods can help you achieve the desired dimensions.
If you need more finishing, you can use different aluminum surface treatments. There are many ways to do this. These techniques can help your HPDC casting parts be more robust and less likely to rust. The most common methods are black or clear anodized aluminum, painting, powder coating, e-coating, and more.
After all this, your HPDC casting parts may need testing for certifications. Note that certifications create customer trust and reliability in real applications.
What are the Key Features of High-Pressure Die Casting?
In the previous section, we discussed the HPDC die-casting process in detail. As you know, in the HPDC casting process, the machine pours molten metal into the die or mold cavity at high pressure and speed. This technically provides several advantages. Let’s check them one by one.
Feature #1 High Precision Metal Parts
One of the best benefits of the HPDC casting process is the precision. Using this tech, you can achieve very high accuracy. According to experts from various industries, this tolerance ranges from ± 0.016mm to ± 0.12mm.
Feature #2 Work with More Complex Designs
HPDC die-casting process also allows you to work with more complex designs. As you know, high-pressure forces molten metal to fill a detailed mold cavity. This means that these molten metals can reach every detail of the design. Most aluminum intricate metal parts are made through the HPDC casting process.
Feature #3 Better Surface Finish
The HPDC casting process also produces a better surface finish. The molten metal fills every corner of the mold cavity under high pressure. Because of this pressure, the density of the metal part also remains the same. Because of this, the surface gets a better result after it cools.
Feature #4 Increased Productivity
The high-pressure die-casting process works very fast. In some manufacturing, this process is fully automated. However, whether manual or automated, it is still faster than other methods. Because of this, you can make hundreds of metal parts in less time. This increases your productivity and reduces costs.
Feature #5 Work with Thinner Wall Products
Again, the high-pressure molten metal fills every corner of the mold cavity. This technology allows you to work with thinner-walled products. Some typical examples are engine components, housings, and heat sinks.
Feature #6 Better Quality
High-pressure casting parts are famous for their high quality and consistency. The controlled process parameters and precise molds always give you uniform castings. This consistent quality ensures better mechanical properties. Specifically, the casting metal parts can have more strength and durability.
Feature #7 Durable Dies
Finally, the tools used in HPDC casting are usually made of good steel. These molds or dies can easily handle high pressure repeatedly. Overall, durable dies eliminate the need for frequent replacement. Once created, they can make thousands of metal parts repeatedly, reducing production costs.
What Materials Are Compatible with High-Pressure Die Casting?
Although HPDC casting can work with most types of metals, it is uncommon. The most common materials people usually use are aluminum, magnesium, and zinc. Ferrous metals are especially not ideal because they are more prone to rust.
Aluminum
Aluminum is one of the most used materials in HPDC casting. This metal has a high strength-to-weight ratio and is 100% recyclable. Aluminum is also famous for its excellent corrosion resistance. Compared to its weight, aluminum can withstand large loads. You may find its use in construction, automotive, and aerospace.
Moreover, aluminum has good thermal and electrical conductivity. Thus, it is often used in house appliances and various electrical gadgets.
Magnesium
Magnesium is also a lightweight metal used in HPDC casting. Although it is not as famous as aluminum, magnesium is also prevalent in many applications. It is especially suitable for use where weight reduction is crucial. You can use it in vehicle seats, trolleys, laptops, or cameras.
Magnesium is strong and easy to machine. You can give it a complex shape and intricate details. In addition, you can use it for various dampening applications.
Zinc
Zinc alloys are another famous material used in high pressure die casting. They are typically renowned for their excellent fluidity and low melting point. However, zinc alloys have better dimensional stability. You can create complex shapes with thin walls.
Zinc alloys are also resistant to impact and suitable for long-lasting performance jobs. They are mainly used in decorations, but other applications include locking tools, gears, and various car parts.
The Use of HPDC Casting in Various Industries
HPDC die-casting parts are prevalent in many industries. They are versatile, and people use them in many applications. Since HPDC offers several features, we can find its use in the following sectors:
Automotive Industry
Automotive is a common place for HPDC castings. Engine blocks, transmission gears, gearbox housings, and other aluminum parts are typical. Like car seats, high-pressure casting can also be used for various structural supports.
As you know, HPDC casting makes strong and light parts, which is very important in the car industry.
Consumer electronics
Another popular place for HPDC casting parts is consumer electronics. You may find these castings in smartphones, laptops, cameras, and other electronic devices.
As you know, the high-pressure casting process ensures these components meet tight tolerances. Other finishing methods can achieve aesthetic appeal.
Medical Equipment
It is crucial in the medical field to use light and precise materials. HPDC casting lets you make metal parts that are of high quality and meet tight tolerances.
Various diagnostic devices and surgical equipment also use HPDC castings. Moreover, various device housings are also made of high-pressure castings.
Defense Industry
The need for lightweight parts is critical in defense. They make military trucks more mobile, faster, and better at using fuel. Because of this, operations are more efficient and easier to move and set up.
Most importantly, lightweight materials provide tactical benefits in various combats. Weapons, military vehicles, and communication gadgets are all examples.
Aerospace Industry
This industry mainly relies on HPDC casting parts. Most airplanes need strong and light parts. Engine parts, housings, and brackets are common HPDC airplane items.
What is Aluminum HPDC Casting?
Aluminum HPDC casting is the most common high-pressure die casting. The process is all the same, but the material is aluminum. However, HPDC aluminum is suitable for various reasons.
HPDC aluminum parts are trendy because they are precise. Their high-quality finish also makes them ideal for many jobs. As discussed in the previous section, people use these parts in many fields.
Also, aluminum HPDC castings are strong and last a long time. They are strong for how light they are compared to their strength. So, you can use them in many places where support is needed, like car seats.
As you know, aluminum HPDC casting works with high pressure and speed. Thus, it can produce hundreds of parts in less time. Therefore, high-pressure aluminum die casting is cheap per unit.
HPDC aluminum alloys are also prevalent in a variety of structural applications. Some of the structural parts of your car are made of HPDC aluminum alloys, as well as the engine blocks and chassis.
Common aluminum alloys used in HPDC include A380, A383, and A360. A380 or A383 are suitable for strength and corrosion resistance. On the other hand, the A360 offers excellent pressure tightness. These alloys have unique benefits in HPDC casting processes.
High-Pressure Die Casting vs. low-pressure Die Casting (HPDC vs LPDC)
Both high-pressure die casting and low-pressure die casting are prevalent in real-world applications. However, each has its unique benefits and uses. We have already learned so much about HPDC. Let’s compare HPDC die casting with LPDC die casting in the following table.
Feature
High-pressure Die Casting (HPDC)
Low-Pressure Die Casting (LPDC)
Process
Molten metal is injected into a die at high pressure and speed.
Molten metal is forced into a die by low pressure and speed.
Pressure range
High (1500 to 25000 psi)
Low (2-= to 15 psi)
Die Construction
Steel dies are used, often complex, multi-part
Steel or iron dies, typically simpler and less complex
Speed
Very fast, suitable for high-volume production
Slower compared to HPDC, leading to longer cycle times
Surface finish
Excellent with smooth surface and fine details
Good, but generally not as tight as HPDC
Accuracy
High, with tight tolerances, usually ranges between ± 0.016mm and ± 0.12mm.
High, not as accurate as HPDC
Complexities
Can produce highly complex parts with thin walls
Suitable for moderate complex parts with thicker walls
Tooling cost
Higher initial cost due to complex dies
Lower initial cost due to simpler dies
Cooling rate
Fast cooling
Slower cooling rate
Typical Alloys
Mostly aluminum, magnesium, and zinc alloys
Mostly aluminum alloys with some use of magnesium and copper
CNM TECH – Custom HPDC Casting Services
CNM TECH is high pressure die casting company in China, it is founded in 1999 and backed by a family that has 18 years of experience in high pressure die casting manufacturing business. This factory generally does cast and different kinds of machining. You can get OEM metal parts, custom metal parts, and other metal parts. One of the main things they do is high-pressure die casting (HPDC).
We offer custom metal parts solutions. Whether you are looking for OEM metal parts, custom HPDC castings, small- to medium-large volume aluminium die casting, magnesium die casting,zinc die casting, or prototypes, CNM TECH is the factory you need. We have the latest machinery and testing equipment and offer various certifications. As a result, we are capable of meeting diverse client needs. Overall, CNM TECH provides reliable and affordable casting services.
With our ISO 9001 certified production and quality control systems, we provide global customers with the highest quality pressure die casting services. In addition, we offer secondary operations and light mechanical assemblies. such as surface finish including powder coating, nodizing, e-coasting, painting etc. CNM TECH. is one of the best internationally known high pressure die casting companies in the world. Our experienced and English-speaking engineers and our worldwide sales staff provide excellent pre-sale and production support.
Services We offer
High pressure die Casting parts and molds in aluminum, magnesium and zinc alloy
Light Mechanical Assembly, including stud and helicoil inserts, O-ring, gasket
Laser Cutting and Engraving
Etching
If you need any supporting in die casting parts you are welcome to contact us, we would happy to support, no matter you need technical supporting or price for your project.
FAQs
Can steel be a pressure die-cast?
You can pressure die-cast stainless steel, but it rarely happens. Aluminum, magnesium, and zinc are popular metals that can be used for high-pressure die casting (HPDC). Steel has a high melting point. Simply put, its qualities make it unsuitable for HPDC casting. You can still do the pressure die-cast, but it might cost more than you thought to make.
What products are made by high-pressure die casting?
You can create a variety of products using HPDC technology. As you know, high-pressure die casting uses high pressure and speed to make each component. As a result, you can create better quality and more complex designs. Some HPDC castings are engine blocks, surgical equipment, laptops, and more.
What is casting pressure in HPDC?
Casting pressure is usually the force used in the HPDC casting process. This pressure usually forces the molten metal to reach every corner of the mold cavity. However, it typically ranges from 1500 to 2500 psi. The exact pressure depends on the type of design and metals.
What grade of aluminum is used for high-pressure die casting?
The most common grade of aluminum used for HPDC casting is A380. The A380 is the most common alloy in die casting because it is strong and easy to work with. This alloy usually has more fluidity than A360. Thus, A380 is more suitable than A360 for the high-pressure die-casting process. Besides, the A380 offers excellent dimensional stability and conductivity.
Summary
High-pressure die casting (HPDC) creates metal parts at high pressure and speed. The pressure usually ranges from 1500 psi to 2500 psi. HPDC casting is a fast and efficient method for making complex shapes.
Aluminum HPDC casting is the most common. A380 aluminum alloy is more prevalent in this case. Aluminum is strong, lightweight, and offers excellent corrosion resistance. Thus, it is often used in many applications.
If you have any questions, feel free to contact us today. We offer all types of casting and CNC machining services, and our team of experts is always happy to assist you.
Different Between Aluminum Die Casting and Gravity Casting
Aluminium Die Casting is more than just an excuse to play with the molten metal it is actually a great way to create art and complicated pieces of machinery or other items that would otherwise be nearly impossible to make. Aluminum die Casting is really a great way to save money…while playing with molten metal.
The reason that aluminum die Casting has survived the test of time is a matter of efficiency. Some of the earliest casting examples have been found in China dating back thousands and thousands of years. In fact, every major civilization from the Egyptians to the Romans practised aluminum casting. This skill came back into vogue during the Renaissance and has continued to advance and evolve from there. While Sand Casting is the most popular casting process there are many, many more processes available to the backyard foundries.
Not everyone is going to be casting heavy pieces like engine parts or cast their own motorcycles. So for those that just want to make decorative pieces, you will not be using the same casting process as these heavy duty casters. For artists creating small scale statues or embellishes and for hobbyists that need a decorative touch to their model plane or boat might want to consider using gravity casting for their needs.
What is Gravity Casting
Gravity Casting seems to be especially useful when dealing with aluminum and other light alloys. The basic idea behind this casting process is pretty much exactly what the name suggests. The metal is introduced into the mold by the force of gravity. Most other casting process either use natural pressure difference like the kind in certain sand casting procedures or they use forced pressure like in centrifugal casting to get the molten metal into the mold.
One of the most common uses for gravity casting is when permanent molds are going to be used. Also called a die, the permanent mold is really only economical for those planning on using the same mold numerous times and will need to keep the quality at a constant level. While some temporary molds can be repeatedly used the quality of the finished product will begin to suffer over time. With die molds the quality will remain the same. Die molds should be seen as an investment. Yes, they will be more costly than other molds; however, they will outlast cheaper options for molds. With Permanent molds, they are created using cast iron, steel, and other metals.
Gravity casting is used for the permanent mold process with pleasing results. Gravity casting is usually used when the finished product is more visually based then structurally based which is why this method is a favourite of artists and even some jewellers. The loss of strength is due to the lack of pressure used in this process. For those that need the strength but still want to use gravity casting, more of the molten metal will need to be used which will increase the weight. go to https://www.aludiecasting.com/ to know more about gravity casting
Relying on gravity will take patience, although it will be needed for larger products.
If you need gravity casting or aluminum die casting, magnesium die casting or zinc die casting service for your business. You are welcome to send us your requirement for quote, you only need to send us your 3D part design and your requirement, then you can sit back and we will do there rest for you, to work with us you only need to take care of the market at your side, and we will be your back up to take care of lead time, shipment, quality and technical.
Are you looking for the high quality and ultimate die casting services for your business? Well, you better need to hire the right service provider who must be experienced in the very same domain. Yes, it is highly necessary to invest some time who can offer very high-quality results and that is by paying the very affordable amount.
Before we talk about how to find the right company, it is highly necessary to know more about Die casting. Well, this is the most important manufacturing technology which is used by many industries which are looking for all sorts of parts to commence the work and for that it is necessary to go with the aluminum die castingprocess. With the help of die casting mold, it will help in molding the complexity of the metal substance exactly in the same manner as you are looking to have. Yes, the final product can have virtually any size depending on what designer desires, thus there is nothing impossible for the best and great service providers at all.
When it comes to finding a right service provider for aluminum casting parts, you better invest time over the net and find out the most experienced, reliable and friendly service provider to meet the exact requirements without any fail. Also, you better find out someone who can easily work on any customized requirements of the clients as well as they must possess great goodwill in the market. Also, you can investigate their previous projects and check how best they are in the die casting and how they have helped other companies to complete their requirements. Not only this, even, you need to disclose them the complete information about your project requirements and check how well they are in offering you the correct guidance as well as what price they are quoting you up. Even, you can do this with different sources and go up with the best one who offers great services at the best prices.
die casting
Moving up with the pro means they will consider mechanical properties, including tensile strength, yield, impact, hardness, and other various specifications in advance to offer you the best solutions. Not only this, pros will help in picking up the right metal which they perform by checking out the physical properties of the metal. Yes, before going up with the aluminum die casting, it is very important to know more about its conductivity or how it behaves under extreme stress or heat. Pros also determine the composition of different alloys, check what are the common uses for the primary element, they also check out a complete list of die-cast alloys, check out the needed properties, and everything to offer you something the best to meet your exact requirements.
Why don’t you check out to go to the suggested source? Well, it will offer you the best services by offering you the casting of metal in the shortest possible of time, will make everything from the scratch and the best part is everything will be done in a budget-friendly manner.
Technology is improving day by day and we are the one enjoying it up fully. Today, we can have every possible thing to make our work the best as well as offer us full convenience and complete peace of mind.
Apart from others, talking about Die casting, it is a manufacturing process that can produce geometrically unique and impossible metal parts with the best use of reusable molds, called dies. The die casting process is very important and pros always make sure to use all the necessary things, called- furnace, metal, die casting machine, die and other various materials. The metal which is used here is always non-ferrous alloy, like- Zinc and aluminum, later it is melted in the furnace and then injected into the dies in the die casting machine for producing very complex metal parts.
It is always better to approach the right company for aluminum casting parts as they always go with the best and authentic procedures in order to produce something the best. They may use different types of die casting machines, called – hot chamber machines and cold chamber machines for a perfect die casting solution. Hot chamber machines are used for those alloys which have low melting temperatures, such as zinc. And Cold chamber machines are used for those alloys with high melting temperatures, such as aluminum. Both machines work the same and once they are done with the molten metal, they inject the same into the dies, wait for cooling it down and solidify into the final part, called the casting.
Aluminum die casting tooling is also known as dies, is here just for alloying the steel. The dies are finished from at least two sections to allow casting elimination. To do so, there is a special need of the efficient approach of die casting and some go with the portable slides, with certain sections that can be done without difficulty to build the ideal shape as demanded by clients from die casters. In the procedure, die casting tooling goes with the simple production of the holes through the predetermined die half. Once we have the molten metal, it is then dispensed into the hole in order to dry in the cavity and this is the best way to get the specific dimensions contoured in the plating. Dies may also have to lock pins, which are utilized in order to stick together two halves and to take away the cast part. Always find the best and reliable service provider for aluminum die casting as well as who can easily manufacture miniature to large precision components using the broad range ofzinc die casting, aluminum and magnesium die casting alloys.
It is important to know that each and every alloy has unique physical characteristics to match your specific application. However, it is highly necessary to find out the right experts who can help you to meet your requirements by picking up the ideal material to manufacture your precision component. If you are looking for further assistance and help or need customized miniature just connect with the suggested source.
d close dimensional limits are important design considerations, 
CNM Die Casting is your one-stop, complete service Die Caster for various die casting parts including aluminum die casting, investment casting, sand casting. We offer you a single source for engineered die castings, together with cutting-edge engineering resources, advanced production capabilities and complete secondary finishing.
