What is die casting?
Die casting is a metal casting process, which is characterized by applying high pressure to the molten metal using the cavity of the mold. Molds are usually made of higher-strength alloys, and this process is somewhat similar to injection molding. Most die castings are iron-free, such as zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys and their alloys. Depending on the type of die casting, you need to use a cold chamber die casting machine or a hot chamber die casting machine.
What are the types of die casting?
The injection chamber is divided into hot chamber die-casting (commonly used for zinc alloy) and cold chamber die-casting (commonly used for aluminum alloy). From the pressure, it can be divided into: low pressure casting (such as automobile wheel shell) and pressure casting (such as our company uses pressure Casting), from the exhaust method is divided into: ordinary die-casting and vacuum die-casting.
(1)Hot chamber die-casting
It means that the pressure chamber is immersed in the liquid metal in the heat preservation melting crucible, and the injection part is not directly connected to the base, but is installed on the crucible. The advantages of hot chamber die casting are simple production process and high efficiency; low metal consumption and stable process. However, the pressure chamber and the injection punch are immersed in the liquid metal for a long time, which affects the service life. And it is easy to increase the iron content of the alloy.
(2)Cold chamber die-casting
The injection chamber and the injection punch are not immersed in the molten metal, but a certain amount of molten metal is poured into the injection chamber, and then the injection is performed. The cold chamber die casting machine is a type of die casting equipment. Its working principle is to pour the molten metal liquid into the injection chamber (into the barrel) through the soup spoon, and then use the injection piston (hammer head) to pour the metal liquid It is a kind of casting equipment that is pushed into the mold at high speed and cooled and solidified under a certain pressure to obtain the finished product. The applicable die-casting metal is usually aluminum alloy, pure aluminum, magnesium aluminum alloy, copper alloy etc.
What are the characteristics of die casting production?
- High production efficiency, mechanized or automated production can be realized
- High dimensional accuracy
- High surface finish
- Good mechanical properties
- Good interchangeability
- Clear outline, thin and complex castings, patterns, patterns, text
- Can be obtained High definition
- Excellent economic indicators
- Low cost of die-casting parts
- Can be used as a combination of parts
- The investment cost of die-casting equipment and molds is high, which is not suitable for small batch production
Pressure Die Casting Materials
Different metals are available for casting. Your choice of materials may depend on cost, weight and performance. Here are some tips
| Material | Tensile Strength (MPa) | Yield Strength (MPa) | Hardness (HB) | Typical Applications |
|---|---|---|---|---|
|
Aluminum Alloy ADC12 |
310–330 |
~130 |
80–90 |
General-purpose die castings, auto/electronic housings |
|
Aluminum Alloy A380 |
320–340 |
~160 |
80–100 |
Engine blocks, transmission cases, power tools |
|
Aluminum Alloy ADC10 |
280–310 |
~120 |
70–80 |
Lighting, electronic housings, appliances |
|
Aluminum Alloy A413 |
240–260 |
~100 |
65–75 |
Hydraulic/pneumatic parts, thin-wall castings |
|
Zinc #3 |
~280 |
~210 |
~82 |
Consumer electronics, small gears, connectors |
|
Zinc #5 |
~330 |
~275 |
~90 |
Structural parts needing strength, automotive fittings |
|
Magnesium AZ91D |
250–275 |
~160 |
~63 |
Aerospace, auto parts, lightweight structures
|
Die casting advantages
The advantages of die casting include excellent dimensional accuracy of castings. Usually this depends on the casting material. The typical value is 0.1 mm for the initial 2.5 cm size, and 0.002 mm for each additional cm. Compared with other casting processes, its casting surface is smooth, and the fillet radius is about 1-2.5 microns. Compared to sandbox or permanent mold casting methods, castings with a wall thickness of about 0.75 mm can be produced. It can directly cast internal structures, such as wire sleeves, heating elements, and high-strength bearing surfaces. Other advantages include its ability to reduce or avoid secondary machining, fast production speed, casting tensile strength of up to 415 MPa, and the ability to cast high-fluidity metals.
Die casting application
| Industry | Applications |
|---|---|
|
Automotive |
Engine blocks, transmission cases, housings, brackets, wheels, gearboxes, steering components |
|
Consumer Electronics |
Smartphone frames, laptop housings, camera components, audio system frames |
|
Industrial Equipment |
Power tool housings, motor enclosures, gearboxes, valve bodies |
|
Aerospace |
Seat frames, brackets, covers, lightweight support structures |
|
Home Appliances |
Washing machine parts, blender housings, fan bases, lighting components |
|
Telecommunication |
Antenna parts, enclosures for transmitters, heat sinks, connectors |
|
Medical Devices |
Structural frames, control panel housings, small instrument casings |
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