Die Casting
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Aluminum Alloys Die Casting Design Guide
What is Aluminum Die Casting?
Aluminum die casting is a metal-forming process that allows for the creation of complex aluminum parts. Ingots of aluminum alloy are heated to very high temperatures until they are entirely molten.
The liquid aluminum is injected under high pressure into the cavity of a steel die, also known as a mold — you can see an example of a mold for automotive parts above. The die is made up of two halves, and after the molten aluminum has solidified, they are separated to reveal the cast aluminum part.
The resulting aluminum product is precisely formed with a smooth surface and often requires minimal or no machining processes. Given that steel dies are used, the process can be repeated many times using the same mold before it deteriorates, making aluminum die casting ideal for the high-volume production of aluminum parts.
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Aluminum Die Casting Tolerance Standards
What Is Die Casting vs. Injection Molding?
The process of making a part is basically the same whether you are using die casting or injection molding. You create a die or mold in the form of the part you want to create. You then liquify the material and use extreme pressure to inject it into the die/mold. You then cool the die/mold with internal cooling lines and die spray on the die cavities. Finally, you open the die and remove the shot.
Although there are some variations in technique, the major difference between die casting and injection molding is that die casting uses some kind of metal, often an aluminum alloy, as the raw material, while injection molding uses plastic or polymers.
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Vacuum Aluminum Die Casting Achieve High Injection Rate
What Is Die Casting?
Die casting refers to a process of manufacturing that makes use of high pressure to input a liquid metal into a steel die that is reusable.
The process of rapidly cooling the metal tends to solidify it to form a final shape.
Which Materials Do You Use for Die Casting Parts?
Some of the materials which you use for diecasting parts include:
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Aluminum Die Casting Services For Electric
What Are The Benefits Of Die Casting Parts?
some of the benefits of die casting parts include:
1. Perfect for rapid and mass production: the die casting parts can be fabricated to form shapes that are complex but accurate.
Due to the casting molds, it is possible to repeat the procedure a lot of times to form die casting identical parts.
2. Durable, stable, and accurate: die casting parts tend to be very strong and thus possible to sustain injections of high pressure.
They are also resistant to heat and stable dimensionally as they maintain close tolerances.
Die casting parts tend to possess a greater degree of permanence as compared to counterparts.
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The Semi-solid Die Casting Process
What Are Die Cast Heat Sinks?
Aluminum die cast Heatsinks are used to cool various electronic components and devices. We can provide companies, suppliers, and individuals with die cast heat sinks in a variety of applications, including:
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The Low-pressure Die Casting Process
How Do You Control Quality During Die Casting Parts Process?
The quality of die casting parts is very important for both the manufacturer and their customers. Therefore, it is very important to ensure strict quality control during the die casting parts process.
Some of the critical points to control quality during the diecasting parts process include:
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The Hot Chamber Die Casting Process
Surface Finish Options for Die Casting Parts
The diecast must have a good surface finish that will promote durability, protection, or aesthetic effect. There are different finishing options you can use for die casting parts. However, choices are based on the size of the cast parts and the alloy you are using.
Painting
Painting is the most common surface finishing technique ideal for many materials. It can be for further protection or aesthetic purpose.
The process involves applying lacquers, paints, or enamel with special consideration for the metal used. Before the addition, clean the surface of the metal to remove impurities such as oil (this also helps in adhesion), add an underlying paint (primer), and the primary paint.
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Benefits of Aluminum Die Casting Services
Which Surface Finishes Can You Apply After Die Casting Parts?
Some of the surface finishes which you can apply after dying casting parts include:
1. Anodizing: it is a protective coating that is non-conductive and seals the die casting parts.it is available in several colors such as black, blue, and red and it is quite affordable in forming a resistance to corrosion and durability.
2. Paint: it is a natural coating that uses powder coat paint on your die casting parts.
When the paint is applied to metal surfaces that are pre-treated or non-treated, you obtain die casting parts that have a great look and are customizable.
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Quality Control Measures for Aluminum Die Casting
Other Alloys Used in Die Casting
Magnesium Die Casting
It has a great weight-to-strength ratio and can be machined easily.
Magnesium die casting is also able to reduce the corrosion of materials used in zinc die casting and remove harmful repercussions of impurities.
The main problem with magnesium diecasting is that it corrodes fast, and this is hard to control.
The most effective way of reducing corrosion is to use surface coating modification on the magnesium die casting parts.
Magnesium die casting also has the disadvantage of requiring a lot of post-production processing.
Its overall production cost is also higher as compared to aluminum or zinc die casting.
