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.
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Die Casting clamping force is the force applied to a mold by clamping unit of HPDC die casting machine. The clamping force must be grater their separating force.
Which applied by the injection of molten metal into the mold
The clamping fore > separating force
How to calculate the separating force (opening force)?
Opening force is the force acting on the cavity to make the die expand during the production of die casting part. The opening force can be calculated by the following formula:
F=PXA
F: opening force
P: specific injection pressure
A: Total projected area
What is Specific injection pressure?
Molten metal is ladled through the shot hole into the cold chamber and the shot plunger pushes the metal into the die. The pressure applied by plunger to push the metal into the die is specific injection pressure.
Injection pressure use for different type of casting:
For standard casting =600 kg/cm2
For technical casting =600−800 kg/cm2
For pressure testing casting =800 kg/cm2
What is projected area?
The anticipated region is a two-dimensional zone estimation of a three-dimensional article by anticipating its shape on the plane.
Total projected area =casting projected area + slide projected area + runner projected area + overflow projected area
Example
Casting projected areas =56000mm2
Overflow + runner projected area =22400mm2 (40% of total casting projected area )
Slide projected area=projected area must be selected in the plane that is normal to be direction of core travel x tanꬾ
Angle of wedge = angle of finger cam angle + 2degree
Force FY = F X Tan ꬾ
ꬾ = angle of wedge lock
Example:
Slide core 1 projected area=area normal to direction of travel × tanꬾ
=5000× tan20 degree
=5000× 0.36
=1800 m2
Slide core 2 projected area=4500×tan 20degree= 1620mm2 so,
Total projected area= 56000+22400+1800+1620mm2
=81820 mm2
What is separating force (Opening force)?
(For technical casting=600−800 kg/cm2)
(800 kg/cm2 =8kg/mm2)
Opening force = specific pressure ×total projected area
=8 kg/mm2 × 81820mm2
=654560 kg/mm2 (1 ton = 1000kg)
=654.56 T
Die clamping force
The clamping force must be grater then the separating force.
Locking force require =F×1.2
=654.56×1.2
=785.472 tons
We select the 900T machine
What is fill ratio, how it is important for selecting machine tonnage?
It is the percent of liquid metal vulnerable chamber contrasted with the absolute volume of the virus chamber. Another method for saying it would be the level of metal contrasted with the level of air exposed to the harsh elements chamber
For Example
50% full (of metal) = 50% air remaining
The level of fill is significant in light of the fact that it is utilized to ascertain the ideal moderate shot speed.
This can have a quality impact on the casting.
Fill ratio (30-40%) is good for automobile die casting component quality.
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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.
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The 1st step is to prepare the die halves for casting by cleaning the faces of each die then applying lubrication or release agent.
Once the die has been prepared, the die halves are closed and clamped together with pressure applied from the die-cast machine.
The clamping force will depend upon the size of the machine but must be more than the opposing force trying to open the die during the casting process.
The injection phase:
The ingots are added to the furnace and kept molten at a set temperature according to the metal being used.
The molten metal is transferred to an injection chamber and injected into the closed die pressure ranging from 1000 to 20,000 psi.
The pressure is maintained while the metal solidifies.
The amount is injected into the die is known as the ‘shot’
The injection of metal into the die is very short, this ensures the metals do not start to solidify before the die is completely filled.
The cooling phase:
After the injection is complete, the molten metal needs to solidify before the die is opened.
The cooling time will depend upon the part geometry as well as the metal thermodynamic properties.
The wall thickness of the parts plays a big factor in the cooling time, the thicker the wall section the longer the cooling time required.
The ejection phase:
After the cooling time has elapsed, the two die halves can be opened.
An ejection mechanism then pushes the solidified casting out of the die.
The force of the ejection will be determined by the size of the part, bearing in mind, the part shrink during the cooling process and tends to stick to the die surface.
Once the part has been ejected, the die can be closed ready for the next injection cycle.
The trimming phase
During the cooling and solidification phase, the casting will solidify as a complete cast unit which includes the part, flash, and any runner system
This excess material must be trimmed off to leave just the main cast product.
Method of trimming includes trim tools, band saw are manually clipping.
Any trimmed metal is either scrapped or recycled if permitted.
Advantages of die casting:
Die casting is fast
Die casting can be produced in seconds each part and quantities of hundreds to thousands of metal parts each day.
Near net shape
Die casting are produced “near net shapes” no matter how complex the shape are how tight the tolerances are.
Lighter weights
Die casting are stronger because of the material surface skin not the thickness of materials so parts can weigh less with thinner casting wall thicknesses.
Die casting is versatile
Many more part shapes and sizes can be produced using the die casting manufacturing process.
Die casting are durable
Die castings parts are metal and have a long service life.
Die castings are inexpensive
Die castings are fast to produce and useless material. Die casting are typically less expensive than most other metal parts manufacturing processes.
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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.
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Your High-Quality Source For Aluminum, Magnesium and Zinc Die Castings; Machined and Finished, Ready For Assembly.
Setting product quality as the company goal, CNM Die Casting has risen to the top of its industry during the past ten years.
Die casting buyers to look to CNM TECH to help reduce reject problems they have encountered with other component part suppliers. A manufacturer of natural gas valves experienced reject levels of up to 40% until they were cast by CNM TECH. Now, very few of their parts fail to meet a rigorous 100% testing level for pressure leaks.
Quality based on engineering experience
At CNM TECH Die Casting company, quality begins with experienced engineering assistance. Consultation on part design and aluminum alloy selection are part of the service. Sometimes minor changes in part design can increase production rates and eliminate potential quality problems. The end result is a better part at a lower unit cost.
To be sure finished die casting parts to meet alloy specifications, both incoming materials and finished product samples are checked on the Jarrell-Ash spectrometer.
Quality that moves with production instead of just a final part check
Production starts after a final part design is accepted. Our quality control program then begins a series of checks to determine that the part has been produced within the specified tolerances. First, alloys are tested to make sure they meet our customer’s specifications. Then, statistical sampling during the casting and machining processes provides an early warning of manufacturing defects and helps to prevent the production of defective finished parts. Inspection frequencies can be predetermined by the job requirements to make certain that the parts you receive are parts you can use.
A Three Coordinate Measuring Machine (CMM) allows completed part dimensions to be checked against computer-stored specifications to assure that accuracy has been maintained throughout the entire production run. Fatigue testing for completed parts can also be carried out under simulated operating conditions if required by the customer.
Whether your specifications call for pressure tightness, critical dimensions and details, or freedom from subsurface discontinuities, CNM TECH quality assurance people have the equipment and training for the job.
A regular inspection program on casting and machining equipment helps us maintain close tolerances. Equipment that’s in top operating condition benefits our customers in both reduced costs and shorter lead times. In-plant maintenance personnel can quickly correct machine problems and smooth production flow.
This online catalogue will introduce you to our capabilities and give you a brief tour of our facility. Over 150 employees share our interest in providing on-time delivery of ready-for-assembly die casting parts and our objective of striving for the highest quality.
CNM TECH engineers are available for consultation at early design stages to help assure finished parts meet tolerance and quality requirements while making economical use of die casting processes.
The dimensional coordinate measuring machine is used to measure castings against specified tolerances.
Proven, rigid quality assurance techniques applied at CNM TECH Die Casting manufacturer can meet the most demanding industrial standards.
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CNM Die Casting has the ability to offer various castings including die casting, investment casting, permanent mould casting, and sand casting for a wide range of alloys, including all die-cast alloys, many permanent mold alloys, and many magnesium alloys.
Our manufacturing processes have been accepted by the world casting market as equal or superior to conventional die casting.
Benefits of the CNM Die Casting Process
Better dimensional control
Improved cross parting line tolerances
Reduction in gas porosity
Improved balance properties of finished rotating parts Use of “cast-in-place” inserts Improved mechanical properties due to effective alloy modification Better wear properties due to smaller grain size microstructure Improved flexibility regarding alloys and types of castings
Machining
CNM Die Casting’s Machining Section utilizes the work cell concept and high-speed flexible machining equipment to complete secondary operations to CNM’s castings so that a part or subassembly is ready to install when it leaves our facility.
CNM Die Casting has evolved and responded aggressively to customer demands for providing high-speed machining and assembly services without initial capital expenditures. By factoring a portion of the cost of the existing equipment into each part, the customer benefits from faster set-ups and minimal initial capital outlays.
CNM Die Casting operates 8 die cast machines, complete in-house die casting mold making and CNC machining in an over 20,000-square-foot facility in DONGGUAN, China.
Our integrated manufacturing capabilities, together with over 100 employees, allow us to be your One-Stop, complete service die caster, and be consistently price competitive, while also maintaining a high standard of quality.
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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.
AlZn10Si8Mg aluminum alloys & AlZn10Si8Mg alloy casting parts
We are a professional die casting company in China, we have produced many die casting parts in AlZn10Si8Mg alloys, if you are looking for aluminum die casting parts in AlZn10Si8Mg alloys, we will be one of your best partners, we do not only produce die casting products in AlZn10Si8Mg alloys, but also may type of aluminum alloys, zinc, and magnesium die castings, contact us to get price.
The thermal treatment of die casting products still represents the best option for the manufacture of die casting parts with high mechanical strength. However, the manufacture of alloy materials suitable for thermal treatment requires special casting measures. AlZn10Si8Mg alloys presented here offer designers specific advantages.
In particular, the AlZn10Si8Mg alloys have a very high 0.2% yield strength. It has been widely used in aviation, aerospace, automotive, machinery manufacturing, marine and chemical industries. With the rapid development of the industrial economy, the demand for aluminum AlZn10Si8Mg alloy welded structural parts is increasing, and the research on the weldability of aluminum alloys is also deepened.
AlZn10Si8Mg alloys have excellent corrosion resistance and are well suited for welding. The high shrinkage of AlZn10Si8Mg alloy in comparison with aluminium – silicone alloys must be taken into account when designing die cast molds.
The requirements for the die casting parts, particularly in consideration of the intended use and the technical feasibility in the casting factory, determine which of the presented alloys should be selected.
As a high pressure die casting manufacturer must focus not only on fulfilling the customer specifications but also the increased customer profits. This includes practical customer advising on site and active identification of customer’s need.
We will fully follow our customer requirement on the alloy material selection, or we will recommend a suitable aluminum alloy base on the customers specification, 100% satisfy our customer is our task, The die casting alloy products includes the primaryaluminium die casting, zinc die casting, magnesium die casting, and sand casting, gravity die casting as well as a number of low pressure die casting.
In the production of alloy vehicle components, industrial parts, The main alloy for use in die casting is AlZn10Si8Mg alloys.
AlZn10Si8Mg alloys are self-hardening with these alloy types, the mechanical properties are achieved after storage of approximately 7 to 10 days at room temperature.
The die casting alloy AlZn10Si8Mg achieves high values for tensile strength and offset yield stress, however, the low ductility limits the application range of the alloy.
In one test series, reduction of the zinc content to Approximate 6 per cent by weight of the AlSi9Zn6Mg achieved a significant increase in the ductile yield.
The Chemical composition of these alloy is shown in Table below
Alloy
Si
Fe
Cu
Mn
Mg
Zn
Ti
Sr
AlZn10Si8Mg
8.5-9.3
0.4
0.01
0.3
0.3-0.5
9.0-10.0
0.10
—
AlSi9Zn6Mg
8.5-9.3
0.2
0.01
0.3
0.3-0.5
6.0-6.7
0.05
0.02
Above the table is Chemical composition of AlZn10Si8Mg alloys & AlSi9Zn6Mg alloys
Below Table shows an overview of the achievable mechanical values between AlZn10Si8Mg & AlSi9Zn6Mg.
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CNM TECH. is a high pressure die casting manufacturer in China founded in 1999 and backed by a family that has 18 years of experience in high pressure die casting manufacturing business.
We specialize in high-quality, small- to medium-large volume aluminium die casting, magnesium die casting, and zinc die castingservices, while also offering other casting and mechanical component manufacturing solutions. 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 CNC machining, surface treatment including powder coating, painting etc. CNM TECH. is one of the best internationally known casting suppliers in China. Our experienced and English-speaking engineers and our worldwide sales staff provide excellent pre-sale and production support.
High pressure die casting process
In this process, the liquid metal is injected at high speed and high pressure into a metal mold. A schematic view of high pressure die casting is given in Figure.
This equipment consists of two vertical plates on which bolsters are located which hold the die halves. One plate is fixed and the other can move so that the die can be opened and closed. A measured amount of metal is poured into the shot sleeve and then introduced into the mould cavity using a hydraulically-driven piston. Once the metal has solidified, the die is opened and the casting removed. Compared to Gravity die casting, both the machine and its dies are very expensive, and for this reason, high pressure die casting is economical only for high-volume production.
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.
