Aluminum Aerospace parts

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.

die casting parts

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.

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:

  1. For standard casting =600 kg/cm2
  2. For technical casting =600−800 kg/cm2
  3. 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.

Zinc die casting

What is Die Casting?

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

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.

Die Casting manufacture company

The climbing phase:

  • 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.Die Casting manufacture company

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.

 

 

Zinc die casting

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

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.

Die Casting Parts

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 finishDie Casting Manufacturered 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.

Die Casting CompanyThis 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.

die casting processCNM 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.

 

Below are Comparison of die casting processes
Metals that can be castMin.and Max mass, kgTolerance
on dim.,%
Surface finish,µ mMin. section size, mmDraft degProduction rate,pcs/hrMin. cored hole,mmPorosity
Sand CastingAluminium
Steel
CI and others
0.03, 100
0.10, 200, 000
0.03, 50, 000
0.09
to
0.03
4
8
8
3
6
3.5
4
to
7
10
to
15
65
Permanent
Mould Casting
Cast iron
Al and Mg
0.01, 50
0.01, 10
0.01
min
25
3
2504.5 to 6
6
4
Die CastingAl
Mg
Zn
0.015, 35
0.015, 35
0.05, 80
0.0015
0.0015
1
1
1
0.8
1.2
0.5
2
2
2
75 to 150

300 to 350

2.5
2.5
0.8
2
Precision
Investment Casting
Steel
Aluminium
0.005, 25
0.002, 10
0.003, to
0.005
1
1
1
0.8
1 to
3
  N/A0.5 to
1.25
1
Shell
moulding
Steel
Cast iron
Aluminium
0.05, 120
0.03, 50
0.03, 15
0.01
to
0.003
6
6
2.5
3.5
3
1.5
2
to
3
30
to
80
3
to
6
1
Centrifugal castingAluminium
Steel
Cast iron
up to
400
0.002
0.004
0.004
0.6
to
3.5
0.6
to
1.2
330
to
50
 N/A1
to

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

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

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.

Permanent Mold Casting

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

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.

high pressure die casting

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

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.AlZn10Si8Mg alloys & AlSi9Zn6Mg alloys

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 primary aluminium 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

AlloySiFeCuMnMgZnTiSr
AlZn10Si8Mg8.5-9.30.40.010.30.3-0.59.0-10.00.10
AlSi9Zn6Mg8.5-9.30.20.010.30.3-0.56.0-6.70.050.02

Above the table is Chemical composition of AlZn10Si8Mg alloys & AlSi9Zn6Mg alloys

Below Table shows an overview of the achievable mechanical values between AlZn10Si8Mg & AlSi9Zn6Mg.

Alloy [Condition]0,2%-Offset Yield Stress RP0.2 [MPa]Tensile Strength RM [MPa]Ductile Yield A5 [%]
AlZn10Si8Mg230-280300-3502-4
AlSi9Zn6Mg160-210280-3305-9

 

aluminum casting and machining

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.

high pressure die casting

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.

prototyping CNC machining

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.

high pressure die casting mold

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 part

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.

FeatureHigh-pressure Die Casting (HPDC)Low-Pressure Die Casting (LPDC)
ProcessMolten metal is injected into a die at high pressure and speed.Molten metal is forced into a die by low pressure and speed.
Pressure rangeHigh (1500 to 25000 psi)Low (2-= to 15 psi)
Die ConstructionSteel dies are used, often complex, multi-partSteel or iron dies, typically simpler and less complex
SpeedVery fast, suitable for high-volume productionSlower compared to HPDC, leading to longer cycle times
Surface finishExcellent with smooth surface and fine detailsGood, but generally not as tight as HPDC
AccuracyHigh, with tight tolerances, usually ranges between ± 0.016mm and ± 0.12mm.High, not as accurate as HPDC
ComplexitiesCan produce highly complex parts with thin wallsSuitable for moderate complex parts with thicker walls
Tooling costHigher initial cost due to complex diesLower initial cost due to simpler dies
Cooling rateFast coolingSlower cooling rate
Typical AlloysMostly aluminum, magnesium, and zinc alloysMostly 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

CNC machining – vertical, horizontal, turning, 5-axis

Prototyping machining

Powder Coating

Liquid Coating

EMI – RFI Shielding

Plating – chrome, copper, zinc, nickel, tin, gold

Anodizing, Electrical Coating, Chromating/Non-chromating

Heat Treatment, Passivation, Tumbling

Graphics

Pad Printing

Bead Blasting

Light Mechanical Assembly, including stud and helicoil inserts, O-ring, gasket

Laser Cutting and Engraving

Etching

If you need any supporting in die casting parts you are welcome to contact us, we would happy to support, no matter you need technical supporting or price for your project.

FAQs

Can steel be a pressure die-cast?

You can pressure die-cast stainless steel, but it rarely happens. Aluminum, magnesium, and zinc are popular metals that can be used for high-pressure die casting (HPDC). Steel has a high melting point. Simply put, its qualities make it unsuitable for HPDC casting. You can still do the pressure die-cast, but it might cost more than you thought to make.

What products are made by high-pressure die casting?

You can create a variety of products using HPDC technology. As you know, high-pressure die casting uses high pressure and speed to make each component. As a result, you can create better quality and more complex designs. Some HPDC castings are engine blocks, surgical equipment, laptops, and more.

What is casting pressure in HPDC?

Casting pressure is usually the force used in the HPDC casting process. This pressure usually forces the molten metal to reach every corner of the mold cavity. However, it typically ranges from 1500 to 2500 psi. The exact pressure depends on the type of design and metals.

What grade of aluminum is used for high-pressure die casting?

The most common grade of aluminum used for HPDC casting is A380. The A380 is the most common alloy in die casting because it is strong and easy to work with. This alloy usually has more fluidity than A360. Thus, A380 is more suitable than A360 for the high-pressure die-casting process. Besides, the A380 offers excellent dimensional stability and conductivity.

Summary

High-pressure die casting (HPDC) creates metal parts at high pressure and speed. The pressure usually ranges from 1500 psi to 2500 psi. HPDC casting is a fast and efficient method for making complex shapes.

Aluminum HPDC casting is the most common. A380 aluminum alloy is more prevalent in this case. Aluminum is strong, lightweight, and offers excellent corrosion resistance. Thus, it is often used in many applications.

If you have any questions, feel free to contact us today. We offer all types of casting and CNC machining services, and our team of experts is always happy to assist you.