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.
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Die casting is a manufacturing process for producing accurately dimension, sharply defined, smooth or textured-surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished product. The term, “die casting,” is also used to describe the finished part.
The term “gravity die casting” refers to castings made in metal molds under a gravity head. It is known as permanent mold casting in the U.S.A. and Canada. What we call “die casting” here is known as “high pressure die casting” in Europe.
First, a steel mold capable of producing tens of thousands of castings in rapid succession must be made in at least two sections to permit removal of castings. These sections are mounted securely in a machine and are arranged so that one is stationary (fixed die half) while the other is moveable (injector die half). To begin the casting cycle, the two die halves are clamped tightly together by the die casting machine. Molten metal is injected into the die cavity where it solidifies quickly. The die halves are drawn apart and the casting is ejected. Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting.
The complete cycle of the die casting process is by far the fastest known for producing precise non-ferrous metal parts. This is in marked contrast to sand casting which requires a new sand mold for each casting. While the permanent mold process uses iron or steel molds instead of sand, it is considerably slower, and not as precise as die casting.
Types of machines for die casting
Regardless of the type of machine used, it is essential that die halves, cores and/or other moveable sections be securely locked in place during the casting cycle. Generally, the clamping force of the machine is governed by (a) the projected surface area of the casting (measured at the die parting line) and (b) the pressure used to inject metal into the die. Most machines use toggle type mechanisms actuated by hydraulic cylinders (sometimes air pressure) to achieve locking. Others use direct acting hydraulic pressure. Safety interlock systems are used to prevent the die from opening during the casting cycles.
Die casting machines, large or small, very fundamentally only in the method used to inject molten metal into the die. These are classified and described as either hot or cold chamber die casting machines.
Hot Chamber die casting machines
Hot chamber machines (Fig.1) are used primarily for zinc, and low melting point alloys which do not readily attack and erode metal pots, cylinders and plungers. Advanced technology and development of new, higher temperature materials have extended the use of this equipment for magnesium alloy die casting.
Figure 1: Hot Chamber Machine. Diagram illustrates the plunger mechanism which is submerged in molten metal. Modern machines are hydraulically operated and equipped with automatic cycling controls and safety devices.
In the hot chamber machine, the injection mechanism is immersed in molten metal in a furnace attached to the machine. As the plunger is raised, a port opens allowing molten metal to fill the cylinder. As the plunger moves downward sealing the port, it forces molten metal through the gooseneck and nozzle into the die. After the metal has solidified, the plunger is withdrawn, the die opens, and the resulting casting is ejected.
Hot chamber machines are rapid in operation. Cycle times vary from less than one second for small components weighing less than one ounce to thirty seconds for a casting of several pounds. Dies are filled quickly (normally between five and forty milliseconds) and metal is injected at high pressures (1,500 to over 4,500 psi). Nevertheless, modern technology gives close control over these values, thus producing castings with fine detail, close tolerances and high strength.
Cold Chamber die casting machines
Cold chamber machines (Fig. 2) differ from hot chamber machines primarily in one respect; the injection plunger and cylinder are not submerged in molten metal. The molten metal is poured into a “cold chamber” through a port or pouring slot by a hand or automatic ladle. A hydraulically operated plunger, advancing forward, seals the port forcing the metal into the locked die at high pressures. Injection pressures range from 3,000 to over 10,000 psi for both aluminum and magnesium alloys, and from 6,000 to over 15,000 psi for copper base alloys.
Figure 2: Cold Chamber Machine. Diagram illustrates die, cold chamber and horizontal ram or plunger (in charging position).
Die casting provides complex shapes within closer tolerances than many other mass production processes. In a cold chamber machine, more molten metal is poured into the chamber that is needed to fill the die cavity. This helps sustain sufficient pressure to pack the cavity solidly with casting alloy. Excess metal is ejected along with the casting and is part of the complete shot.
Operation of a “cold chamber” machine is a little slower than a “hot chamber” machine because of the ladling operation. A cold chamber machine is used for high melting point die casting alloys because plunger and cylinder assemblies are less subject to attack since they are not submerged in molten metal.
Die casting and their construction
Die casting dies (Fig. 3) are made of alloy tool steels in at least two sections called fixed die half and ejector die half. The fixed die half is mounted on the side toward the molten metal injection system. The ejector die half, to which the die casting adheres, and from which it is ejected when the die is opened, is mounted on the moveable platen of the machine.
The fixed die half of the die is designed to contain the sprue hole through which molten metal enters the die. The ejector half usually contains the runners (passageways) and gates (inlets) which route molten metal to the cavity (or cavities) of the die. The ejector half is also connected to an ejector box which houses the mechanism for ejecting the casting from the die. Ejection occurs when pins connected to the ejector plate move forward to force the casting from the cavity. This usually occurs as part of the opening stroke of the machine. Placement of ejector pins must be carefully arranged so force placed upon the casting during ejection will not cause deformation. Return pins attached to the ejector plate return this plate to its casting position as the die closes.
Fixed and moveable cores are often used in dies. If fixed, the core axis must be parallel to the direction of die casting mold opening. If moveable, they are often attached to core slides. Should the side of a die casting design require a depression, the die can be made with one or more slides to obtain the desired result without affecting ejection of the casting from the die cavity. All moveable slides and cores must be carefully fitted, and have the ability to be securely locked into position during the casting cycle. Otherwise, molten metal could be forced into their slideways causing a disruption of operations. Although slides and cores add to the complexity and cost of die construction, they make it possible to produce die castings in a wide variety of configurations, and usually more economically than any other metalworking process.
Type of die casting molds
Dies are classified as: single cavity, multiple cavities, combination and unit dies (Figures 4-A to 4-D).
A single cavity die requires no explanation. Multiple cavity dies have several cavities which are all identical. If a die has cavities of different shapes, it’s called a combination or family die. A combination of die is used to produce several parts for an assembly. For simple parts, unit dies might be used to effect tooling and production economies. Several parts for an assembly, or for different customers, might be cast at the same time with unit dies. One or more unit dies are assembled in a common holder and connected by runners to a common opening or sprue hole. This permits simultaneous filling of all cavities.
Advantages of die casting
Die casting component parts, decorative trim, and/or finished products offer many features, advantages and benefits to those who specify this manufacturing process.
Die castings are produced at high rates of production. Little or no machining is required.
Die castings can be produced with thinner walls than those obtainable by other casting methods … and much stronger than plastic injection moldings with the same dimensions.
Die casting provide parts which are durable, dimensionally stable, and have the feel and appearance of quality.
Die casting dies can produce thousands of identical castings within specified tolerances before additional tooling may be required.
Zinc die castings can be easily plated or finished with a minimum of surface preparation.
Die castings can be produced with surfaces simulating a wide variety of textures.
Die-cast surfaces, as cast, are smoother than most other forms of casting.
Holes in die castings can be cored and made to tap drill sizes.
External threads on parts can be readily die cast.
Die castings provide integral fastening elements, such as bosses and studs, which can result in assembly economies.
Inserts of other metals and some non-metals can be die cast in place.
Corrosion resistance of die casting alloys rates from good to high.
Die castings are monolithic. They combine many functions in one, complex shaped part. Because die castings do not consist of separate parts, welded or fastened together, the strength is that of the material, not that of threads or welds, etc.
Die Casting process can producealuminum die casting, magnesium die casing, zinc die casting, brass die casting , lead casting and so on, and all of those can be easily massive produced.
Die casting is an efficient, economical process which, when used to its maximum potential, replaces assemblies of a variety of parts produced by various manufacturing processes at significant savings in cost and labour.
Comparisions with other products
Plastics injection molding Parts
Compared with plastic injection molding Parts, die castings are the stronger, stiffer, more stable dimension, more heat resistant, and are far superior to plastics on a properties/cost basis. They help prevent radio frequency and electromagnetic emissions. For chrome plating, die castings are much superior to plastic. Die castings have a high degree of permanence under load when compared to plastics, are completely resistant to ultra-violet rays, weathering, and stress-cracking in the presence of various reagents. Manufacturing cycles for producing die castings are much faster than for plastic injection moldings. Plastics, however, may be cheaper on a unit volume basis, have colour inherent properties which tend to eliminate finishing, are temperature sensitive, and are good electrical insulators.
Sand castings
Compared with sand castings, die castings require much less machining; can be made with thinner walls; can have all or nearly all holes cored to size; can be held within much closer dimensional limits; are produced more rapidly in dies which make thousands of die castings without replacement; do not require new cores for each casting; are easily provided with inserts die cast in place; have smoother surfaces and involve much less labor cost per casting. Sand castings, on the other hand, can be made from ferrous metals and from many non-ferrous alloys not suitable for die casting. Shapes not producible by die casting are available in sand castings; maximum size can be greater; tooling cost is often less and small quantities can be produced more economically. you can check more sand aluminium casting
Permanent mold castings
Compared with permanent mold castings, die castings can be made to closer dimensional limits and with thinner sections; holes can be cored; are produced at higher rates with less manual labour; have smoother surfaces and usually cost less per die casting. Permanent mold casting involves somewhat lower tooling costs; can be made with sand cores yielding shapes not available in die casting.
Forgings
Compared with forgings, die castingscan be made more complex in shape and have shaped not forgeable; can have thinner sections; be held to closer dimensions and have coring not feasible in forgings. Forgings, however, are denser and stronger than die castings; have properties of wrought alloys; can be produced in ferrous and other metals and in sizes not suitable for die castings.
Stamping
Compared with stamping, one die casting can often replace several parts. Die castings frequently require fewer assembly operations; can be held within closer dimensional limits; can have almost any desired variation in section thickness; involve less waste in scrap; are producible in more complex shapes and can be made in shapes not producible in stamped forms. Stamping, on the other hand, have properties of wrought metals; can be made in steel and in alloys not suitable for die casting; in their simpler forms, are produced more rapidly; and may weigh less than die castings.
Screw machine products
Compared with screw machine products, die castings are often produced more rapidly; involve much less waste in scrap; can be made in shapes difficult or impossible to produce from the bar or tubular stock, and may require fewer operations. On the other hand, screw machine products can be made from steel and alloys which cannot be die cast; they have the properties of wrought metals, and they require less tooling expense.
https://www.thediecasting.com/wp-content/uploads/2018/08/high-pressure-die-casting-part.jpg7681170adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2018-10-13 22:41:192024-09-13 17:10:38What Is Die Casting
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.
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Aluminum die casting is a casting liquid die forging method. Die casting process is a kind of special high pressure die casting machine to accomplish the process. Its basic technological process is: first metal or aluminium alloy liquid in low or high-speed casting filling into the die mold cavity, die with a moveable type cavity surface.
It with the liquid aluminum alloy cooling process pressure forging blank, both the elimination of shrinkage defects, also make the rough internal Aluminum Die Casting organization to forge the broken crystal. Rough comprehensive mechanical properties are improved significantly.
A380 aluminium die casting
Benefits of aluminum die casting Metals and precautions related to aluminium die casting. Different types of aluminium alloys can be used in die Casting and aluminium molds, types of methods are used for aluminum casting molds, zinc die casting, aluminum die casting and many more
Type of Casting process
Casting is the process of making Aluminium suitable for producing different types of products. It is a simple and inexpensive way to provide a wide variety of aluminium products. Some of the examples are Washington Monument, car engines, and power transmissions, etc, which were all produced through aluminum casting alloys process. Aluminium casting can be done in 3 ways:-
Auminum die casting
Mold Casting
Sand Casting
DIE CASTING
Die casting is a manufacturing process for producing metal parts. In die casting, die or mold cavities are created with hardened tool steel that has been previously machined to a particular shape. Here in die casting, Aluminium is melted first and is poured into a steel die under high pressure forcefully. This manufacturing technique is normally used for high volume production, the process we normally called high pressure die casting or pressure die casting process
MOLD CASTING
About mold casting, mold and cores can be of either steel or any other metal. Here also the aluminium is melted first and is poured in the mold provided. Sometimes vacuum is also applied. In some situations, Permanent mold casting is seemed to be stronger than both die casting and sand casting methods. Semi-permanent mold casting techniques are used when permanent cores are impossible to remove from the finished part.
Sand casting is the most versatile method of producing aluminium products. Usually, the molted aluminium is poured into a mold which is virtually pressed into a fine sand mixture. The pattern will be little larger than which needed for the aluminium shrinkage during solidification and cooling. Sand Casting is usually a slow process than both die casting and mold casting. Usually, it is used for small quantity products.
Aluminum Casting Alloys
The most important cast aluminum casting alloys system is Al-Si. Here high levels of Silicon contribute to give good casting characteristics. aluminum casting alloys are widely used in engineering structures and components where lightweight or corrosion-resistant is required.
Methods and benefits of Aluminium die casting
Metals and precautions related with aluminium die casting Different types of aluminium can be used for die Casting, Aluminum casting manufacturer & aluminum casting is used in order to cover different types of metals by using different types of methods.
There are many methods used for aluminum casting and different types of benefits are obtained. With the help of aluminum casting and aluminum die casting it is possible to increase the life of metals and these can be used for a long time period with an amazing look and charm of metal.
Methods
Different types of methods are used for aluminium die casting. The main thing is to melt aluminum. High temperature is needed for melting aluminum. Special structures are used for the melting of aluminum. When aluminum casting is melted then it is poured on the target metals. Then the melted aluminum casting is allowed to get hard and it is ready to be used after some time period.
There are special containers that are made to be used for the melting of aluminum. These structures are available in the market in different shapes and sizes. You are also able to make these structures at home by using the desired ingredients. You have many options in making these structures. If you are going to buy this structure from the market then you have to make a selection of the size and shapes. There are many options in terms of sizes and shapes and different types of prices are charged by makers.
Working of these structures is also different as some use fuels and some use manual efforts for getting heat to make sure that aluminum casting could be heated and melted effectively. High temperatures are obtained in these structures and then aluminum casting is melted and then used on the target metals for the casting process.
aluminium die casting
Benefits Aluminium Die Casting
There are many types of benefits of aluminum die casting. Mainly this type of casting is done to make sure that the metal can remain safe from corrosion. Atmosphere conditions and moisture is bad for iron and casting can help to protect iron and increase its useful life. aluminium die castingis able to resist moisture and other harmful effects of the environment due to which it can be used on metals through casting.
The protective shield is made on iron to make sure that it can be used for a long time period. aluminium die casting companies can be cast on iron and make a protective sheet. This protection is in the form of a shining layer which is obtained by using high temperatures. This layer is permanent and good looking along with increasing strength and useful life of metal. Mostly iron is cast with the help of aluminum. This is a cheap process and the user is able to get benefits as the life of iron is increased.
Conclusion
aluminium die casting mold can be used for casting of iron and other metals. There are many methods available for this process. With the help of any reliable method, the user is able to get benefits as the metal is saved from corrosion and other harmful effects of the environment. A protective layer is made as a result of casting and this layer is of aluminum. With the help of this layer, the metal can be used for a long time period.
Type of Aluminum Die Casting
Metals and precautions related to aluminum die casting
Metals and precautions related to aluminum die casting Different types of aluminium can be used for die Casting, Aluminum die casting manufacturer & aluminum casting Different types of metals can be protected with the help of aluminum casting and aluminum die casting. There are different types of care and precautions which are to be used to make sure that the user can get benefits while using the casting process.
The casting of aluminum casting molds is mainly done to make sure that the metals can get a good look and these can remain safe from harmful effects from the environment. Problems like corrosion of iron and other adverse effects of the environment are resisted effectively with the help of aluminum casting and aluminum die casting.
Aluminum Casting Molds
A protective layer of aluminum casting molds is obtained as a result of aluminum casting and aluminium die casting. This layer is made of metals to make sure that these can remain safe from problems. In order to make such a layer, it is important to melt aluminum casting molds. Such metals can be cast with the help of aluminum which has more melting points as compared with aluminum.
This is important as aluminum die casting is to be used in the melted form and if the metals used are having a low melting point then these will be melted and cannot be cast. Those metals which have more melting points as compared with aluminum casting molds can be cast effectively. In this manner, a protective layer of aluminum casting molds is made on metals, which is giving them more life and safety from corrosion and other harmful effects of the environment.
The type of aluminum die casting material
There are many type of aluminum die casting alloy materials that uses to produce aluminum die casting products, and each country have its own name, below we will list some aluminum die casting alloys which are mostly used globally.
A380 aluminum alloy: This aluminum alloy is the most commonly used aluminum die casting alloy. It has excellent casting properties, offers good strength and hardness at high temperatures, and is relatively inexpensive.
Metals Type Analysis
Nominal Value
Unit
Type Analysis
Aluminum (Balance)
80.3 to 83.3
%
Copper
3.00 to 4.00
%
Iron
1.30
%
Magnesium
0.100
%
Manganese
0.500
%
Nickel
0.500
%
Other Elements
0.500
%
Silicon
7.50 to 9.50
%
Tin
0.350
%
Zinc
3.00
%
A383 aluminum alloy: Similar to A380, A383 offers improved thermal properties and is more resistant to heat-related warping. It is used for parts that require higher levels of heat resistance and thermal stability.
Metals Type Analysis
Nominal Value
Unit
Type Analysis
Carbon
< 0.0250
%
Chromium
27.0
%
Copper
1.00
%
Manganese
1.00
%
Molybdenum
3.50
%
Nickel
31.0
%
Phosphorus
< 0.0250
%
Silicon
0.800
%
Sulfur
< 0.0200
%
A360 aluminum alloy: This aluminum alloy is similar to A380 but contains more silicon. It provides improved fluidity, making it a good choice for complex parts that require thin walls or intricate designs.
Metals Type Analysis
Nominal Value
Unit
Type Analysis
Aluminum (Balance)
86.0 to 87.2
%
Copper
< 0.600
%
Iron
< 1.30
%
Magnesium
0.400 to 0.600
%
Manganese
< 0.350
%
Nickel
< 0.500
%
Silicon
9.00 to 10.0
%
Tin
< 0.150
%
Zinc
< 0.500
%
ADC10 and ADC12 aluminum alloy: These are two Japanese aluminum die casting alloys that are similar to A380 and A383, respectively. They offer excellent casting properties, high strength, and good corrosion resistance.
Metals Type Analysis
Nominal Value
Unit
Type Analysis
Aluminum (Balance)
80.3 to 83.3
%
Copper
3.00 to 4.00
%
Iron
1.30
%
Magnesium
0.100
%
Manganese
0.500
%
Nickel
0.500
%
Other Elements
0.500
%
Silicon
7.50 to 9.50
%
Tin
0.350
%
Zinc
3.00
%
A365 aluminum alloy: A365 aluminum alloy is known for its high strength-to-weight ratio, good corrosion resistance, and good machinability. It is commonly used in the manufacturing of aerospace and aircraft components, such as landing gear and structural parts, as well as in automotive and industrial applications.
Metals Type Analysis
Nominal Value
Unit
Type Analysis
Carbon
0.150 to 0.200
%
Chromium
10.0 to 11.5
%
Manganese
0.500 to 0.800
%
Molybdenum
0.800 to 1.10
%
Nickel
0.300 to 0.600
%
Niobium
0.350 to 0.550
%
Nitrogen
0.0400 to 0.0800
%
Phosphorus
< 0.0200
%
Silicon
0.200 to 0.600
%
Sulfur
< 0.0150
%
Vanadium
0.150 to 0.250
%
Each of these materials has unique properties and benefits. When selecting a material for die casting, it’s important to consider the specific needs and requirements of the application to select the most appropriate material.
Precautions casting
When you are using a casting process then make sure that you have all the required tools and items. You have to protect your body from extra heat which is generated in the casting process. Melted aluminum must be handled with care as it can fell and lead to hardening and accidents. You must pour the melted aluminum on target metals and give enough time for hardening.
You must have the tools which can be used for handling melted aluminum. The tools to be used must be hard enough that these could bear the high temperatures of melted aluminum. You must have special clothes which will cover your body to remain safe from the heat. With some care, you are able to use the casting process to give your metals a new life. The useful life of different types of metals can be increased with the help of casting of aluminum.
The casting of aluminum casting molds is used on different types of metals for increasing their useful life. Aluminum is able to make a thin sheet which is giving protection to metals. This layer is obtained by melting aluminum casting molds and then pouring the melted aluminum casting molds on the surface of target metals. Different types of metals are cast in a routine with the help of casting of aluminum. You must have the tools and items to be used to complete the casting process.
With some care, you are able to get desired results in the form of casted items and metals which will give you long term benefits. You must understand the casting process and learn it before trying it. When you have the knowledge and items for completion of the casting process then you can try this at home.
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