This article introduces the die casting process, available aluminum die casting materials, advantages, applications, and limitations of high pressure die casting. Let’s continue reading to gain a deeper understanding of this technology.
High Pressure Die Casting Process
Mould Design
This is the first step. CEX Casting provides internal mold design and manufacturing services.
We provide mold flow analysis and DFM reports to predict potential defects before actual production and optimize die casting mold design to minimize the likelihood of production issues.
Mold Preparation
Before casting begins, the mold should be thoroughly cleaned and lubricated to prevent adhesion and ensure smooth ejection.
Preheating molds helps reduce thermal shock, improve metal flow, and ensure consistent quality.
Centralized Melting
CEX Casting is equipped with a centralized melting and purification system for raw materials to remove excess impurities and gases, ensuring the quality of molten metal.
Molten Metal Injection
Molten die casting aluminum, zinc, or magnesium is injected into the mold at a speed of 100 m/s.
The applied pressure range is 1500 to 25000 psi, which ensures complete filling of the cavity.
In addition, high-pressure injection can reduce air retention and significantly lower the porosity of the product.
Cooling and Solidification
CEX Casting provides a unique cooling design that allows molten metal to cool evenly in the mold.
Integrated cooling channels help control temperature and minimize the possibility of cracking.
Ejection
After the metal solidifies, the top rod pushes the casting out of the mold. Excess materials, such as burrs and flow channels, are removed by a cutting machine.
Then deburring and shot blasting are carried out to obtain the final casting blank.
Subsequent Precision Machining
CEX Casting invested dozens of CNC machining equipment that can achieve a maximum tolerance of ± 0.01mm and a surface roughness of Ra 0.6um.
Surface Treatment
CEX Casting can provide a variety of surface treatment services, including powder coating, spray painting, electroplating, hot plating, electrophoresis, oxidation, etc., and provide corresponding services according to customer requirements.
Materials for High Pressure Die Casting
Materials for High Pressure Die CastingAluminum Die Casting Materials
Aluminum is the most commonly used HPDC material because of its light weight, corrosion resistance, and high strength-to-weight ratio.
Common aluminum die casting materials grades: ADC12, A380, A383, A360, etc.
Zinc Alloy
Zinc has excellent fluidity and high precision, making it an ideal choice for complex and intricate designs.
Common die cast zinc alloy grades: Zamak 2, Zamak 3, Zamak 5, etc.
Magnesium Alloy
Magnesium is highly valued for its lightweight and high strength, as well as its excellent shock absorption and processability.
Common die cast magnesium alloy grades: AZ91, AZ31, AM60, etc.
Advantages of High Pressure Die Casting
● High Production Efficiency: Short production cycle makes it an ideal choice for large-scale production.
● Good Dimensional Accuracy: Reduces the need for secondary processing.
● Fine Surface Finish: Smooth surfaces are suitable for surface treatment.
● Complex and Thin-Walled Parts: Can produce parts with complex geometric shapes and uneven wall thickness, providing a high degree of design flexibility.
● Material Efficiency: Compared to machining and forging, die casting aluminum can minimize waste and allow for metal recycling.
Application of High Pressure Die Casting
Automotive Industry
High pressure die casting is widely used in engine cylinders, transmissions, wheels, and brackets, providing a lightweight and robust solution to improve fuel efficiency.
Consumer Electronics
Smartphone frames, laptop cases, and heat sinks benefit from aluminum die casting’s excellent thermal conductivity and ability to produce complex parts.
Industrial Machinery
Die casting process is used for precision casings, mechanical components, and other customized industrial parts, such as motor housing, gearbox housing, and engine mount.
Challenges and Limitations
● High Initial Mold Cost: Compared to sand casting, the mold cost is relatively high.
● Possibility of Porosity: Proper gate design and exhaust technology are needed to minimize defects as much as possible.
● Thermal Fatigue of Molds: Repeated heating and cooling can shorten the lifespan of molds.
● Not Suitable for Small Batches: Due to high mold costs and fast production speed, this process is suitable for large batch orders.
CEX Casting provides regular mold maintenance services, and customers only need to bear the mold cost once. We are responsible for the subsequent mold maintenance services.
In addition, our special cooling and exhaust system can ensure the castings are even cooled to minimize internal porosity.
Conclusion
High pressure die casting (HPDC) is an efficient manufacturing process that, despite challenges such as mold costs and potential porosity, remains the primary method for producing complex-shaped components in automotive, mechanical, and electronic applications.
As a leading die casting manufacturer, CEX Casting offers one stop die casting aluminum solutions to meet your project needs.
Contact us immediately to learn how our expertise in aluminum die casting can benefit your next project!