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Die-casting Definition


 

Die casting is a fabricating procedure where the liquid metal is infused into a mold cavity which is manufactured by two hardened steel dies that have been machined to the specified component shape with high precision.

This allows each component to be created with accuracy and repeatability. Aluminum, zinc, and magnesium are the most commonly used die casting alloys.

Aluminum die casting components are frequently considered when large volumes are required, parts must be lightweight with high quality or the environment operation temperature is high and eroding

Die-Cast Process

 

There isn’t one single process that can suit every project. Each project is different which is why Vietnam Outsourcing offers multiple solutions for all die casting needs. This ensures the right process is always used for the right application. At Vietnam Outsourcing, we offer three different types of die casting processes.

Hot-Chamber Die Casting

 

Cold-Chamber Die Casting

Used for zinc, some magnesium alloys, and other low-melting, hot-chamber die casting is a great option for alloys that do not readily attack and erode metal pots, cylinders, and plungers.

 

Hot-Chamber Die Casting

When the port seals, the metal rests in the cavity to cool and solidify. Next, the plunger retracts and the casting itself can be removed once the die opens. This design allows the hot chamber die casting to be a continuous process.

Because the melting pot is internal, hot chamber machinery is used for materials with lower melting points. The alloys are also limited to materials that won’t erode or dissolve the metal of the machine when put under heat or high pressure. Typical materials used in hot chamber die casting are zinc, lead and magnesium alloys.

 

Better suited for metals with high melting points such as aluminum, during cold-chamber die casting, metal is liquefied and then ladled into a cold chamber where a hydraulically operated plunger pushes the metal into the die.
 

Cold chamber die casting

Molten metal must be ladled into the chamber directly, either through a ladle system or manually. Once the molten metal is loaded to a sufficient volume, it will be injected into the die through a high-pressure hydraulic plunger. Pressure requirements for cold chamber castings are typically higher than those of hot chamber die castings.
 

Cold chamber die casting can also take as short as seconds for the die to solidify, though other simple designs take just a few minutes. Cold chambers are typically built to contain multiple cavities, so different machine parts can be created at the same time — either duplicates or a variety of different parts in the same mold.

 

How to do die casting

The high pressure die casting process consists of four steps, including mold preparation, filling, injection, and shake out, which are also the basis for various improved die casting processes.

1.Preparation

Die Casting Process: PREPARATION

In the preparation process, it is necessary to spray a lubricant into the cavity. In addition to helping to control the temperature of the mold, the lubricant can also help to remove the casting, and then the mold can be closed.


2.Filling

Die casting process: FILLING

The molten metal is filled into the mold with a high pressure, which is in the range of about 10 to 175 MPa. When the molten metal is filled, the pressure is maintained until the casting solidifies.


3.Injection

Die Casting Process: Injection

 

•The dies are then opened and the shot (shots are different from castings because there can be multiple cavities in a die, yielding multiple castings per shot) is ejected by the ejector pins.

•High-pressure injection results in a very fast filling of the mold so that the molten metal can fill the entire mold before any part solidifies. In this way, surface discontinuities can be avoided even in thin-walled sections that are difficult to fill.

•Most die castings can be used to perform structures that cannot be completed by casting, such as drilling and polishing.

4.Shakeout

Die Casting Process: Shake Out

The process of shakeout requires separating the scrap, including gates, runners, sprues, and flash. This process is usually done by extruding the casting through a special dressing die. Other sand falling methods include sawing and grinding.


5.Defect Inspection

Die Casting Process: Defect inspection

•Defects can be checked after the shakeout process is completed. The most common defects include stagnation and cold heading.
 

Die casting Hot Chamber and Cold Chamber - a comparison

Die casting is an efficient manufacturing process used to mass-produce parts in a wide range of shapes, and these parts make their way into common items in our homes and workplaces

cold chamber die casting
 

Cold Chamber Die Casting Basics

Cold chamber die casting is a preferred manufacturing process for metals that have high melting points, and it’s used by most of the top parts manufacturers in the industry. Typically, this will include metal alloys of aluminum, brass, and copper. Cold chamber machinery requires additional equipment — usually an outside furnace and a ladle to pour the metal into the machine — for die casting. However, this allows the process to use materials that may be stronger and have versatile industrial applications.

 







hot chamber die casting


Understanding Hot Chamber Die Casting  

Hot chamber machinery contains the alloy melting pot as part of the machine itself and uses a gooseneck to inject material from the pot into the die. Internals of the machine pair the plunger and port to control how much-molten metal is injected into the die.


 








 

Die casting vs Shell Molding

Both shell molding and die casting can produce various types of intricately shaped products quickly and can be scaled to produce large amounts of products.

Die Casting or Shell Molding?

Shell molding offers the advantage of supporting both ferrous and non-ferrous metals, while die casting is most often used with non-ferrous metals. If you need to use a ferrous metal, such as steel or iron, shell molding may be the right choice. Die casting, however, produces less waste because it does not require the use of sand and resin. The equipment costs and tooling costs for die casting are typically higher than those associated with shell modling.

Both shell molding and die casting are reliable processes that can be used to create accurate, high-quality parts. The best way to know which one is right for your project is to talk with a professional. They can review the details of your project and help you determine the ideal processes to use.

 

DIE CASTING - APPLICATION

High-pressure Die Casting for a Wide Variety of Industries
Vietnam Outsourcing's Partner can perform high-pressure die casting for companies in a wide range of industrial applications including:

  • Medical:  surgical instruments, hospital equipment, hospital bed gearboxes and peristaltic  pumps.
  • Recreational Vehicles:  recreational vehicle manufacturers.
  • Traffic lights:  manufacturing of housings for street and traffic light enclosures, PED boxes and aluminum light enclosures.
  • Outdoor lighting:  outdoor lighting products including walk light housings, bullet light fixtures, coach lights and wall sconce fixtures. 
  • Firearms: firearms industry, die casting trigger guards, and shotgun and rifle parts.
  • Industrial equipment: compressor and piston connecting rods, porter cable pump housings, wall mount bearing housings, industrial pumps, air compressors and many others. 
  • Telecommunications: telecom industry products such as electrical housings, connecting front face plates, waveguides, antenna mounts and RF filters.


 
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