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Email: info@ace-machinery.com

DIE CASTING

 
Die casting is one of the most economical and fastest forming processes. The advantage of this production method is that thousands of castings can be produced quickly by using only one die casting mold. All components produced are of uniform quality and the unit cost is relatively low.

What is Die Casting

Precision die casting is a manufacturing process that can produce metal parts with complex geometries by using reusable molds. The die casting process involves the use of furnaces, metals, die casting machines, and molds. The die casting metal, usually non-ferrous alloys, such as aluminum or zinc, is melted in a furnace and then injected into the die of the die casting machine.

Types of Machines for Die Casting

Depending on the type of molten metal, part geometry, and part size, different die casting processes can provide different die casting parts. The two main types of the die casting process are hot chamber die casting and cold chamber die casting. Regardless of the casting machine used, it is important to lock the mold halves, cores, and other movable parts firmly in place during the precision die casting cycle.
 

Hot Chamber Die Casting

The hot chamber die casting machine is characterized in that the cylinder cavity of the injection mechanism is completely immersed in the molten metal bath. The gooseneck metal feed system draws the molten metal into the mold cavity where the melt is pressed by the piston into the closed die casting mold at high speed. This process is used for low melting point alloys such as zinc, lead, or tin.

The furnace is connected to the machine through a feeding system called a gooseneck. As the cycle begins, the piston will retract, which allows molten metal to fill the “gooseneck” from the port in the injection cylinder.

When the plunger moves down, it seals the port and forces molten metal into the mold through the gooseneck and nozzle. After the metal solidifies, the plunger will pull up.

After that, the mold will open and the part pops up. The advantage of this method is the short cycle time because it does not require the transportation of metal from a separate furnace.

Among the two main die casting processes, hot chamber die casting (sometimes called gooseneck die casting or hot casting) is more popular. Compared with the cold room process, this process can improve the productivity of parts.

Cold Chamber Die Casting

Due to the slow operation, the operation of the cold chamber die casting machine is a bit slower than that of the hot chamber machine. Cold chamber machines are used for high melting point casting alloys such as aluminum, brass, and magnesium.

The main difference between cold chamber machines and hot chamber machines is that the injection plunger and cylinder are not immersed in the molten metal. Because the plunger and cylinder assembly are not immersed in the molten metal, they are less eroded.

Pour the molten metal into the “cold chamber” through the port or pouring trough by hand or automatic ladle. The hydraulic plunger that is advanced seals the port, forcing the metal into the locked mold under high pressure.

Aluminum and magnesium alloys have injection pressures ranging from 3,000 to 10,000 psi and copper-based alloys from 6,000 to 15,000 psi.

For applications that are too corrosive for the immersion design of hot chamber die castings, the cold chamber process may be a good choice. In cold chamber machines, more molten metal is poured into the chamber than needed to fill the mold cavity. This helps maintain enough pressure to fill the cavity with cast alloy firmly.

Die Casting Alloys

Aluminum Alloys

Aluminum’s strength, corrosion resistance, and heat dissipation provide obvious advantages for mechanical designers. Our proprietary thin-wall aluminum die casting technology makes aluminum die castings the choice for more applications. Aluminum can also withstand the maximum operating temperature of all die-cast alloys.

Cast aluminum is versatile and corrosion-resistant. It maintains the high dimensional stability of thin walls, so aluminum casting alloy can be used to manufacture components with thin walls and complex shapes. They are generally stronger and lighter than most zinc-based castings but are often more expensive to manufacture.

Zinc Alloys

Zinc die castings are used in hot-chamber machines. Zinc-based casting alloys are the easiest to die cast with high ductility and excellent impact strength, making them suitable for being die casting into various products. Zinc alloy die castings provide thin walls and excellent surface smoothness, making preparation for electroplating and spraying relatively easy.

Custom zinc die castings are usually used instead of cast iron or brass, but the tensile strength is often low. Unless special reinforcement is applied during the alloying process, the force per square inch of the zinc-based material must not exceed approximately 17,000 pounds. Therefore die cast zinc products are generally not used in applications involving high mechanical loads.
 

Magnesium Alloys

Magnesium die casting alloys are known for their low weight, high strength-to-weight ratio, excellent damping capacity, and ease of processing. Magnesium casting alloy is almost lighter than plastic and is a completely recyclable and strong alloy. Used in applications that require lightness and durability, it is the easiest metal to casting.

ACE BEST can cast high-quality magnesium die castings for you. We provide customized magnesium casting parts and components in the automotive, food, dairy, machinery, medical, pipeline, watering, mining, petrochemical, and other industries and applications.

Service We Offer

Aluminum Die Casting

We’re an ISO 9001:2008 certified aluminum die casting manufacturer that specializes in custom aluminum die casting services for the world’s leading industries and companies.
 

Zinc Die Casting

We specialize in delivering advanced miniature custom zinc die casting services for high-precision manufacturing of smaller, complex parts and components.
 

Magnesium Die Casting

Whether it is a prototype, mold design or a long-term production relationship, ACE BEST has extensive knowledge and expertise to provide the advantages of custom magnesium die castings.
 

Die Casting Design

Ace Best offers a variety of options for customized die castings. We provide complete die casting design services to ensure that the final product is very suitable for your specific application.

CNC Machining

Ace Best Die Casting offers in-house CNC machining as a complement to our die casting services. These CNC machines use a tailored approach to manufacture custom-made die casting parts that are ready for product assembly.

Metal Finishing

Our metal finishing services include vibratory deburring that can effectively remove sharp edges and other imperfections from the surface of the product.

Application

Currently, various die casting manufacturing industries rely on one or more types of die casting processes. Die casting can be used in the automotive, aerospace, power tools, and other industries. Specific applications include:

● Connector housing
● Gear
● Engine block
● Gearbox housing

● Oil pan
● Engine bracket
● beam
● Compressor

● Telecommunications and electronic parts
● measuring instrument
● Water pump
● Sink faucet

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We welcome your cooperation and we will develop with you.

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