Die Casting:
Die casting is a method to produce product parts with intricate geometrical patterns and an aesthetic appearance by using a steel mold or die cavity.
It is almost the same procedure as injection molding, which involves the insertion of molten plastic material into the mold cavity. The molten material takes the form of the mold and becomes a solid material on cooling. Then the part is extracted out from the mold to be processed further for an attractive look.
In the same way, die casting is the most popular method to produce product parts with high-quality and durability. It has metal parts with rich quality and precision that makes sure the process to be reiterated many times.
The factors that assist the die casting in taking place are the furnace, molten metal material, casting instrument, and the die or mold itself. The most commonly employed alloys for die casting are zinc, aluminum, and magnesium.
Die Casting Service at First Part:
At First Part China Limited, we produce high-volume metal parts with complex geometrical patterns and aesthetic designs. High-quality, durability, rapid outcome, and fidelity are our main considerations to carry out the projects.
We offer pressure die casting service, which the most affordable method to manufacture production parts with high-quality, durability, repeatability, dimensional accuracy, and high-tolerance.
Our professional engineers have ten years of experience that enable us to provide rapid turnaround by producing 1 million parts with affordable costs depending on the size, geometrical-complications, dimensional complexities, and intricate parameters.
What are The Types of Die Casting?
The main purpose of die casting is to cast a mold using injected metals in molten form. Depending upon the part geometry, part magnitude, and part dimensions, there are two main types of die casting.
(1) Hot-Chamber die casting (Hot Casting)
(2) Cold-Chamber die Casting (Cold Casting)
Hot-chamber die casting is also known as gooseneck casting or Hot-Casting. It is a more popular method than Cold- Chamber die casting. In this procedure, the introducing mechanism’s cylinder chamber is thoroughly submerged into the melted metal bath; the gooseneck metal feed system draws the molten metal into the die cavity.
The cylinder chamber’s direct contact with the gooseneck metal feed system permits rapid and easy mold introduction. Consequently, then products become vulnerable to corrosion. This method is suitable for metals with lower melting points and high fluidity.
The best suitable metals used in this procedure are lead, magnesium, zinc, and copper.
Cold-Chamber Die Casting:
It is a similar procedure for Hot-Casting. This method’s main objective is to minimize on minimizing corrosion rather than the efficient production of the products. In this method, melted metal is introduced spontaneously or hand-allocated into the injection system.
It decreases the necessity for the injection system to be submerged in the molten metal bath. It is an excellent alternative method for the manufacture of metallic parts to Hot-chamber die casting because it saves the corrosion of immersion designs.
This is the best-suited method to cast metals with high temperatures, such as Aluminum and its alloys.
Advantages of Die Casting:
Following are the major advantages of die casting.
High Quality:
The die casting process increases the life of the products and produces rich quality product parts. It produces parts with high accuracy, repeatability, durability, and minimal costs.
High Reliability:
It minimizes the need for modifying the components. The instruments used in die casting are well dimensional-oriented to produce millions of copies of the mold part without defects in design, geometry, and dimensions.
Quick Production:
It takes less time for the manufacturing process. It can handle bulk projects by producing many parts depending on the size, geometrical complexity, and dimensional patterns.
Variety in Designs:
It produces many mold parts of complex geometrical designs, intricate patterns, and sizes without any demerit in the casted parts.
Ease of Assembling:
Assembly features such as studs, drill holes, and bosses can be embedded into mold cavities. It makes it easier to assemble a large number of parts with minimal time expenditure.
Applications of Die Casting:
Following industries have applications of die casting.
1、Robotics
2、Automotive
3、Education
4、Aerospace
5、Defense
6、Electronics
7、Medical
8、Dental
9、Energy
Die Casting Accuracy:
The accuracy of the casted parts depends on the following factors.
1、Dimensional stability
2、Draft angles
3、Fluidity
4、Tolerances
5、Selecting the right casting manufacturer
1.Dimensional Stability:
Zinc alloys have exceptional dimensional stability during the process of casting. For zinc metal alloys like ZA-27, specific considerations are essential to fulfill the requirement of tolerances. Before choosing a manufacturer for your project, make sure that he is professional to qualify your project’s expectations.
2.Draft Angles:
Before finalizing the draft angles, you and your supplier must consider the taper of the die’s taper to bring out the part from the cavity. Zinc alloys may have less draft angle during the process of casting as compared to other materials.
Zero draft angles can be kept to cast the parts in certain conditions. It is beneficial to produce parts in moving mechanical contacts like gears, where zero draft angle permits to make product parts with inexpensive costs.
3.Fluidity:
Zinc alloys have extraordinary casting fluidity, due to which they possess exceptional castability with thin-walls. It permits the production of 0.15mm thick walls for die-cast components and 2.3mm for molds’ continuous casting.
This characteristic can produce lighter and smaller product parts with complex geometries and cheap tooling costs.
4.Tolerances:
The casting of zinc alloys allows us to manufacture high-volume and correct product parts. It helps to produce mold-components with high-tolerances. We hardly find any other process that can provide the same net shape representation due to this characteristic.
It reduces the need for machining and secondary processing. Therefore, it is also a cost-effective method to produce mold parts.
5.Selecting the Right Casting Manufacturer:
Before starting the die casting project, it is essential to choose the right manufacturer who is capable of optimizing the design of your dies and components. It ensures high-accuracy, repeatability, aesthetic geometrical patterns, and minimal costs of the parts.
