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.
https://www.thediecasting.com/wp-content/uploads/2019/09/Zinc-die-casting.jpg250305adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2019-09-28 14:25:252019-09-20 14:42:18The importance of zinc die casting in the automotive industry
Zinc die casting Parts is referred to as the hot-chamber process. It is the method by which zinc (zamak) is heated under high temperatures and the molten material forced into a zinc die casting mold under high pressure to produce product with a similar shape as the die. As the metal moves through the die, air escapes through the vents. Once the die is full, the high pressure is maintained until it solidifies and the die is separated to release the finished zinc cast. After casting, no further modification is usually required.
Zinc (zamak) is known for its high strength, accuracy, ductility, ease of casting, high thermal and electrical conductivity, and long life. As such, the zinc die casting is applied in the manufacture of high quality industrial and building materials. Die casting started in the automotive industry and it is still widely used in the manufacture of automotive components. The door locks casing, pulley, and the camshaft are some of the car parts that are made of zinc casting. In the construction industry, zinc die casting is utilized in the manufacture of components such as door knobs, faucets, and roofing. On the other hand, there are many zinc casting machine parts, such as electrical fittings.
Zinc Die Casting Process
Zinc is cast using the hot-chamber process due to its low melting temperatures. Cold chamber process is applied in the casting of metals with high melting temperatures such as the aluminium. The zinc die casting process involves the preparation of the metal, die preparation, and finishing. It commences with the preparation of the die followed by the metal. Notably, the die can be used once or severally depending on the component being manufactured. If it was used before, it should be lubricated to ease the removal of the cast metal. Afterwards, the ejector die half and the cover die half are screwed. The cover die half has a sprue through which the molten metal is injected while the ejector die has ejector pins for removing the castings.
Preparation of the die is followed by melting of the ZA or the ZAMALAK alloy on a furnace. The physical properties of the product dictates the choice of the alloy. Due to metal hardness and strength, the furnace temperature is usually very high. The oxidized parts of the metal are removed at this stage to raise the purity of the finished product. Various chemicals can be added to improve physical properties of the finished alloy.
Once the molten metal is prepared, it is injected into the feed system under high pressure. Most of the systems have several dies for efficiency and mass production. The raised pressure ensures that the molten zinc alloy gets into the mold as fast as possible, no air gets into the molten metal, and the expulsion of the air in the die through the vents. After filling the die, the pressure is raised further until the zinc alloy casting solidifies. The process also involves cooling using water. Then, the two dies are separated and the metal cast is removed. This is followed by the cleaning of the feed system to get rid of the flash. Further finishing can be carried out depending with the final use of the product. The runner that is removed from the final product and the flash are usually recycled.
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Machining and Finishing Operations For Ready-To-Assemble Die Casting Parts.
Over 20 years, CNM die casting company, Incorporated has provided high-quality aluminum, magnesium, and zinc die casting parts and services. CNM TECH specializes in the design, engineering, and production of complex die-cast parts in a broad range of sizes. Our experienced team of engineers, technicians, designers, machinists, finishers, and production staff excel at producing precision castings that are meticulously machined to tight tolerances, finished to customer specifications, and delivered ready for assembly.
Regardless of quantity, part type, alloy, cast-and-trim to cosmetic finish, CNM TECH is a solution driven die-casting partner that works with you to produce the best possible products cost-effectively and efficiently.
In order to supply ready-to-assemble component die casting parts, CNM TECH Die Casting manufacturer maintains a fully-equipped production machine shop. It’s staffed with machinists experienced in working with aluminum and zinc. Here, modern machine tools, supported by regular maintenance and a statistical process control program, can turn out production quantities of high-quality parts to meet your manufacturing schedules. CNM TECH has the capability of handling machining requirements where tolerances must be held to a few ten-thousandths of an inch and where production quality control records must be provided.
CNM TECH also maintains close working relationships with local suppliers of a variety of finishing services such as plating, anodizing and painting. This assures you of a smooth flow of work through a single, responsible source and, at the same time, provides access to a wide variety of finishing options.
Inventory capabilities to meet your just-in-time production needs.
CNM TECH warehouses parts inventories for customers with just-in-time production schedules. Once a predetermined inventory level has been established, we can set manufacturing schedules to maintain the stock you require. Actual parts delivery is aided by our central location and easy access to interstate highways.
Let’s talk about the difference that quality can make in your die casting parts.
If you’re interested in lowering your current casting reject rate or if you feel your part quantities are reaching a volume that can justify die casting, please give us a call. We’ve invested a lot of ourselves in maintaining tight quality control standards and we’d like to put that investment to work for you.
Finished parts can be packed to any specification for timely delivery anywhere in the country. CNM TECH’s location puts the entire upper Midwest within the overnight delivery time.
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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.
https://www.thediecasting.com/wp-content/uploads/2019/05/Die-Casting-Parts.jpg300375adminhttps://www.thediecasting.com/wp-content/uploads/2020/06/cropped-Aluminum-die-casting.jpgadmin2019-05-02 23:40:182019-06-08 11:40:52High Quality Die Casting Parts
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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CNM Die Casting is your one-stop, complete service Die Caster for various die casting parts including aluminum die casting, investment casting, sand casting. We offer you a single source for engineered die castings, together with cutting-edge engineering resources, advanced production capabilities and complete secondary finishing.
CNM Die Casting supplies high-quality aluminum, zinc, brass and magnesium die castings. We operate our casting factory in DongGuan, China for various castings, machining, assembly and die building, with over 20,000 square feet of total floor space.
We are a leader in innovative quality control systems. Our quality manufacturing system includes a process failure detection system
at every casting press. Rigorous 100% inspection is as much a production operation as any other manufacturing step and is woven into the sequential standardized work to assure manufacturing quality in finishing and machining.
As one of the divisions of CNM Manufacturing Group, CNM Die Casting can be more responsive to its customers and, simultaneously, offer more competitive, “made in China” pricing on quality products.
CNM Die Casting’s tooling department builds dies with state-of-the-art equipment.
Along with our experienced engineering and tooling department, we design tooling and assist customers with casting design issues. Excellent control of design and tool building allows us to produce high quality tools and parts at lower cost, and more quickly than anyone else in the industry.
Our Engineering and Tooling Department offers:
Tool Engineers to ensure specifications and dimensional criteria are met to the customer’s requirements
Design Engineers with the latest CAD/CAM technologies to design both product and tooling for the customer’s specification.
Technical on-site product design assistance for die castings
Production tooling built with CNC machines by in-house full capability large tooling facility state-of-the-art
EDM machines rapidly burn cavities to near-finished condition with oscillating feed.
Prototyping in the same tooling intended for production
Production tools are built with premium grade materials
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.
A380 aluminum die casting has become a significant part of the manufacturing industry in recent years. This process involves the use of A380 aluminum alloy, which is known for its lightweight and high strength properties, making it a desirable material for die casting.
In this article, we will explore the properties, advantages, applications, production process, quality control measures, limitations, and future developments of A380 aluminum die casting. By the end of this article, you will have a comprehensive understanding of this manufacturing process and its potential impact on various industries.
I. What is A380 aluminum die casting
A. Definition of A380 aluminum die casting
A380 aluminum die casting is a manufacturing process that uses molten A380 aluminum alloy to produce complex-shaped parts through the use of molds. This process is highly flexible, allowing for the creation of intricate parts that are difficult to produce using other casting methods.
B. Brief history of A380 aluminum die casting
A380 aluminum alloy was developed in the early 1950s and quickly gained popularity due to its lightweight and high strength properties. Since then, A380 aluminum die casting has become a prominent manufacturing process, especially in the automotive and aerospace industries.
C. Significance of a380 die cast aluminum in the manufacturing industry
The use of A380 aluminum die casting has revolutionized the manufacturing industry, allowing for the creation of complex parts that would have been difficult to produce using conventional methods. This process has enabled manufacturers to reduce production costs while maintaining high-quality standards.
This article aims to provide a comprehensive understanding of A380 aluminum die casting, including its properties, advantages, applications, production process, quality control measures, limitations, and future developments.
A380 die casting aluminum
II. Properties of A380 aluminum alloy
A. Overview of aluminum alloys
Aluminum alloys refer to a group of alloys that are primarily composed of aluminum. These alloys are known for their lightweight and corrosion-resistant properties.
B. Chemical composition and mechanical properties of A380 aluminum alloy
A380 aluminum alloy is composed of 8.5-9.5% silicon, 3-4% copper, 0.1% magnesium, 0.5% iron, and 0.5% zinc. This alloy exhibits high strength, excellent corrosion resistance, and good thermal and electrical conductivity.
C. Advantages of using A380 aluminum alloy in die casting
A380 aluminum alloy is lightweight and has a high strength-to-weight ratio, making it an ideal material for producing complex parts. It also has excellent corrosion resistance, allowing it to withstand harsh environments and conditions. Additionally, A380 aluminum alloy has good thermal and electrical conductivity, allowing for efficient and effective heat transfer.
D. Comparison with other aluminum alloys
Compared to other aluminum alloys, A380 alloy has a higher silicon content, giving it superior casting properties. It is also more cost-effective than other high-strength aluminum alloys such as 7075.
III. Advantages of using A380 aluminum die casting
A. Lightweight and high strength properties
The use of A380 aluminum die casting allows for the production of lightweight parts without sacrificing strength. This material is ideal for industries such as automotive and aerospace, where weight is a crucial factor in determining product performance.
B. Excellent corrosion resistance
A380 aluminum alloy has excellent corrosion resistance, making it an ideal material for parts that are exposed to harsh environments and conditions. This material can withstand exposure to extreme temperatures, saltwater, and various chemicals, making it an ideal choice for marine applications.
C. Good thermal and electrical conductivity
A380 aluminum alloy has good thermal and electrical conductivity, allowing for efficient and effective heat transfer. This makes it an ideal material for electronic components, where heat dissipation is critical for product performance.
D. Complex geometries and design flexibility
A380 aluminum die casting allows for the creation of complex-shaped parts with intricate details that would have been difficult to produce using other casting methods. This process offers high design flexibility, allowing manufacturers to produce unique parts that meet specific requirements.
E. Economical production cost
A380 aluminum die casting is a cost-effective manufacturing process that allows for the production of high-quality parts at a relatively low cost. This process offers fast production rates, reducing production costs while maintaining high-quality standards.
IV. Applications of A380 aluminum die casting
A. Automotive industry
The automotive industry extensively uses A380 aluminum die casting in the production of engine blocks, transmission cases, suspension components, and other complex parts. The lightweight and high strength properties of A380 aluminum alloy make it an ideal material for producing parts that improve vehicle performance.
B. Aerospace industry
The aerospace industry uses A380 aluminum die casting to produce structural parts for aircraft, such as wing components, engine covers, and landing gear. The lightweight and corrosion-resistant properties of A380 aluminum alloy make it an ideal material for aerospace applications, where weight reduction is critical for fuel efficiency.
C. Medical equipment industry
The medical equipment industry uses A380 aluminum die casting to produce components such as medical devices, equipment frames, and instrument cases. The lightweight and high strength properties of A380 aluminum alloy make it an ideal material for medical equipment that requires portability and easy maneuverability.
D. Electronic industry
The electronic industry uses A380 aluminum die casting to produce components such as heat sinks, housing units, and other electronic parts. The good thermal and electrical conductivity properties of A380 aluminum alloy make it an ideal material for electronic components that require efficient heat transfer.
E. Other applications
Other industries that use A380 aluminum die casting include the construction industry for producing architectural hardware, the military for producing weapons and equipment, and the marine industry for producing ship components.
V. Production process of A380 aluminum die casting
A. Preparation of die casting moulds and machine
The die casting machine is prepared by heating the mold to a specific temperature, which can range from 200 to 500 degrees Celsius. The mold is then coated with a lubricating agent to facilitate the release of the casting after solidification.
B. Pouring of molten
A380 aluminum alloy The heated mold is clamped together, and molten A380 aluminum alloy is poured into the die cavity. The molten metal fills the cavity, taking on the shape of the mold.
C. Cooling and removal of casting
After the mold has been filled, the molten metal is allowed to cool and solidify. The cooling time can vary depending on the size and complexity of the casting. Once the casting has solidified, the mold is opened, and the casting is removed.
D. Post-casting processes
The casting is then cleaned of any excess material and undergoes various processes such as trimming, deburring, and surface finishing to achieve the desired shape and finish.
E. Optimization of production process
To optimize the production process, manufacturers can use various methods such as simulation software to analyze and optimize the design of the casting and the production process. This helps to minimize errors, reduce production time, and improve the quality of the finished product.
VI. Quality control measures for A380 aluminum die casting
A. Testing techniques and equipment
Various testing techniques and equipment are used to ensure the quality of A380 aluminum die casting. These include X-ray inspection, ultrasonic testing, and visual inspection.
B. NDT (non-destructive testing)
Non-destructive testing methods such as X-ray and ultrasonic testing are used to detect any defects in the finished product without causing damage. This helps to ensure that the final product is of high quality and meets required specifications.
C. Quality standards and certifications
A380 aluminum die casting must meet specific quality standards and certifications such as ISO 9001 and QS 9000. Compliance with these standards is essential to ensure that the final product meets required specifications.
D. Ensuring product consistency and reliability
Manufacturers must ensure that their production process is consistent and reliable, producing consistent products that meet required specifications. This helps to ensure that products are of high quality and meet customer needs.
VII. Limitations of A380 aluminum die casting
A. Restricted compatibility with certain alloys
A380 aluminum alloy is not compatible with certain alloys, limiting its use in some industries.
B. Susceptibility to porosity and shrinkage defects
A380 aluminum alloy is susceptible to porosity and shrinkage defects, which can affect the quality of the finished product. Manufacturers must take measures to prevent or minimize these defects.
C. Limitations on minimum wall thickness
A380 aluminum die casting has limitations on the minimum wall thickness that can be achieved. This can restrict the design of certain parts.
D. Environmental impact
The production process of A380 aluminum die casting can have a significant environmental impact due to the energy-intensive manufacturing process and the generation of waste materials.
VIII. Future developments in A380 aluminum die casting technology
A. Advancements in aluminum alloys
Advancements in aluminum alloys, including A380, will likely improve their properties, making them more suitable for various applications.
B. Development of new die casting methods
New die casting methods are emerging that could improve the efficiency and quality of A380 aluminum die casting. These include vacuum and high-pressure die casting.
C. Automation of production processes
Automation could become more prevalent in A380 aluminum die casting, improving efficiency and reducing production costs.
D. Exploration of new applications
As A380 aluminum die casting technology improves, new applications may emerge, expanding the potential uses of this process.
IX. Conclusion and recommendations
A. Summary of key points
A380 aluminum die casting is a manufacturing process that uses A380 aluminum alloy to produce complex-shaped parts. This process offers numerous advantages, including lightweight and high strength properties, excellent corrosion resistance, good thermal and electrical conductivity, complex geometries, design flexibility, and economical production costs.
B. Importance of A380 aluminum die casting in the manufacturing industry
A380 aluminum die casting has become an essential manufacturing process in various industries, including automotive, aerospace, medical equipment, electronics, construction, and marine.
C. Recommendations for businesses considering A380 aluminum die casting for their products
Companies considering A380 aluminum die casting should work with reputable manufacturers to ensure high-quality products. Manufacturers should have the necessary quality certifications and comply with required standards.
D. Final thoughts
A380 aluminum die casting is a versatile and cost-effective manufacturing process that offers numerous advantages. With advancements in aluminum alloys, die casting methods, and automation, A380 aluminum die casting has the potential to transform various industries in the years to come.
Since the year of its inception in 1999, CNM Die Casting China manufacturer specialized in manufacturing of aluminum die casting, zinc die casting, precision machining and other post manufacturing service, we have diversified to aluminum die casting, recently. And this has borne rich dividends both in terms of customer satisfaction and company revenue.
Aluminum Die Casting That Provides Quality and Performance
We at CNM Die Casting’s aluminum department have a reputation of offering our customers the exact die casting aluminum specifications. This has been possible due to our state of technology studio, which is equipped with 21 machines ranging in clamping tonnage from 400 to 1200 tons. We cast aluminum castings up to 45 pounds in 360 alloys and up to 13 pounds in 380 alloys. Our aluminum and zinc departments use central melt furnaces and an efficient launder system to transfer molten metal safely and with the consistency of temperature necessary for process control. To complement our launder system, we have fully automated cells which assure shot to shot consistency like:
Aluminum Capacity, 10g to 125kg
Aluminum Die Cast Dies weight up to 30 Tons
Tymac Process Controls
Vacuum Assist
4000kg. To 135,000kg. Furnace Capacity
ADC 12, 360, 380 Material, or any other special material base on customer requirement
Aluminum Die Casting Equipment That Delivers Excellence
Die casting aluminum is our forte and our cold-chamber die casting machines are typically used to conventionally die cast components using aluminum alloys.
In order to achieve high productivity and good dimensional accuracy, we at GC Die Casting are furnished with
A380 aluminum die casting is our speciality that provides an excellent combination of material properties and ease of production.
Aluminum Die Casting Equipment That Generates Cost Effectiveness
Over the last few years, St Clair die casting has offered its services of aluminum die casting components for a wide range of markets. This includes industry sectors like an appliance, automotive, electronics, and instruments etc. And the demand is only growing higher every day, the reason for this burgeoning need is our quality services coupled with prices that are best in the industry. Order with us to believe us! And we assure you long term dependability and quality.
To know more about our products and services, you can call our Customer Service by +86 3388 9978 or send us an email by sales@thediecasting.com
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 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 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. CASTING DIES 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. TYPES OF DIES
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. COMPARISONS 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.
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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 Die Casting is your one-stop, complete service Die Caster for various die casting parts including aluminum die casting, investment casting, sand casting. We offer you a single source for engineered die castings, together with cutting-edge engineering resources, advanced production capabilities and complete secondary finishing.
