What Is Die Cast Manufacturing?
Die casting is the manufacturing process versatile for producing engineered parts with complex shapes by pouring or forcing molten metal under high pressure into reusable steel molds. The long-lasting steel molds for each project are aimed at building a high-precision and efficient production cycle; hence, each component is created with accuracy and repeatability in the die-casting process. In addition, with molding lifespan reaching up to 80,000 times, die casting is regarded as the most efficient choice for both mass production and customized order.
TYPES OF ALLOYS USED IN DIE CASTINGS
Non-ferrous metal alloys are used as die casting alloys, and most elements of an alloy generally are Al, Si, Fe, Cu, Mg, Mn, Zn, and Ni. The composition of an alloy determines its characteristics (melting and boiling points, physical properties) and performance for manufacturing over various industries. As a result, it creates wide applications for die casting field. customers/designers' requirements are met with sophisticated customization, while certain flexibility is maintained based on the professionality of the manufacturer.
Enlisted are certain common alloys:
1. Magnesium Alloy
Magnesium alloys are used for their excellent strength-to-weight ratio for the die casting process. Amongst other alloys, it's lighter and has a great stiffness rate. These properties are best suited for "thin" structures with narrow tolerance. Magnesium RFI and EMI are great for small components such as "connectors" and "electrical housings". Another reason to consider when adopting Magnesium alloy is the cost. Magnesium is cost-friendly and therefore widely recommended in various industries.
2. Aluminum Alloy
MOST RECOGNIZED
Aluminum alloys are light weighted and easy to adjust with different metals. They are helpful for hardness and fluidity customization.
Aluminum has been the most recognized alloy for die casting these days. Considering its lightness and dimensional stability, it is suitable for both thin walls and complex structures. Aluminum alloys are light weighted and easy to adjust with different metals. They are helpful for hardness and fluidity customization. Low-density aluminum metal is also used by industries. Aluminum has excellent mechanical properties, good corrosion resistance, thermal and electrical properties. All these properties are helpful for the components that will face thermal and electrical energies.
Aluminum alloys are commonly lighter weight than zinc. These alloys are adopted with a mildly higher material cost. However, if added with metal as Magnesium, its tensile strength would improve without affecting the cost.
3. Zinc Alloy
Zinc alloys are the most used alloys because they are easy to cast and their fluidity rate against the molding process is excellent. A wide range of industrial components adopts zinc alloys in die casting methods. Zinc alloy has excellent mechanical properties which make it suitable for electrical and thermal components. In hot chamber casting, zinc is preferred because of the lower melting point compared with aluminum.
DIFFERENT TYPES OF DIE CASTING
Die casting process over the last decade’s improvement, has developed into a design-oriented manufacturing method. Depending on the adopted type of metals, the finishing sizes, and the design geometry, the goals of die casting are fulfilled in flexible ways and results are delivered in excellent stability. The main types of die casting include hot chamber die casting, cold chamber die casting, and injected assembly. There is further variation in these types that involves semi-solid die casting, squeeze die casting, low pressure die casting and vacuum die casting.
1. Hot Chamber
Hot chamber process (also known as hot casting or gooseneck casting) is the most popular type for die casting. This process includes immersion of the cylinder chamber of the injection mechanism into the molten bath of metal. The molten metal is then drawn into the metal cavity with the help of a gooseneck feed system. The main advantage of hot chamber die casting is the constant connection of the casting chamber with the liquid alloy. This type is suitable for metals with low melting points such as zinc.
2. Cold Chamber
This process is somehow similar to the hot casting process. There are specially designed machines for cold chambers which keep the casting set outside the metal. This machine design minimizes corrosion, and the metal is hand ladled into the injection system. The component is produced by pressing the alloy into the die casting mold with the help of channels. This type is suitable for metals having high melting points such as aluminum and copper.
3. Injected Assembly
This process consists of the injection of molten metal into the die. The molten metal is maintained at a particular temperature in the furnace. The metal transfer will depend on the type of die casting machine, whether the cold or hot chamber machines are in use. The metal is injected into the die at high pressure after transfer.
Do you know with the increasing amount of die casting of aluminum, the damage to the mold will become a problem? Click here and get advice from TEAMSWORLD experts for a better balance between production costs and casting quality. We will be happy to help you narrow down your pain points and tailor a solution for you.
BENEFITS OF DIE CASTING
The key advantages of die casting process include the production of die casting parts with smooth surface finish, precise dimensional tolerance, and fine detail at high production rates. Furthermore, casting parts are easy for post-processes such as milling, lathing, surface plating (coloring), sandblasting, painting, and even anodization. Hence, for a product that emphasizes quality both in appearance and performance, die casting is the preferred method that can flexibly realize both mass production and mass customization.
The significant benefits prove that, in many modern industrial fields, die casting is the well-established and broadly applied technology over other manufacturing processes, such as sand casting, extrusion, injection, and lost wax molding. For example, several large automotive die castings are produced by the cold chamber die casting process for its cost-effectiveness in high volume manufacturing, and some aluminum die-casting lighting fixtures are produced by cold chamber die casting process for high melting point and corrosive properties of aluminum.
TEAMSWORLD, MORE THAN A DIE CASTING MANUFACTURER
TEAMSWORLD, in alliance with selected Taiwan factories, has a great capability to provide premium die-casting products with its complete manufacturing capacity and experience, including:
Over 20 sets of die-casting machines of brands TOYO, UBE, Italpresse, and TOSHIBA. (Machine Tonnage: 125-1850 Ton).
Precise machining equipment CNC vertical machining center, milling machine, grinding machine, etc.
The major parts TEAMSWORLD produces at the united facilities include lighting parts, automobile parts, machinery parts, and electromechanical parts. And over 20 years, TEAMSWORLD exports 2 million of these parts yearly to the US, Germany, and various corners of the world.
Looking for premium quality die casting and plastic injection parts? Or in demand for a free alternative material suggestion? Take TEAMSWORLD, determined to optimize manufacturing efficiency from lead time, quality, price to communication for customers, as a must-consult manufacturing partner. Get in touch with our professional team with your questions and prevent your pain points from going worse.