Talking About Die Casting Mould

Today let us talking about the Die Casting Mould:

1. What is Die Casting?

Die casting is one of the main metalworking process for metal castings. It is operated by forcing molten metal under high pressure into a die cavity. Generally speaking, die casting molds are firstly precision machined to net shape or near net shape of finished die cast parts. Material of such molds for die casting is hardned tool steel. Manufacturing of die casting moulds will allow products to be made with perfect accuracy and repeatibility. And, the die casting process will also produce fine details such as textured surfaces or names without requiring further processing.

Die casting is a wise selection for mass production products for its ability to produce high detailed and high accuracy parts. In our daily life, we can see lots of products made in die casting process. When you turn the faucet, you open the door knob, when you drive your car, almost every product or part of the product you use in your daily life is produced using this process.

The die casting process usually produce parts using primarily non-ferrous metals, such as zinc, copper, aluminum and magnesium. For steel and iron castings, investment casting and sand casting can be used.

2. Advantages of Die Casting

Freedom of size – With die casting process, we are able to parts with a wide range of shape and sizes. Unlike other manufacturing processes such as forging, the die casting process does not limit the shape of parts and in most cases will be the net shape of the parts.

Durability – Compared to plastic parts, die castings are stronger than their plastic counterparts. In most cases, even if thinner parts, die casting can still maintaining its strength for its application. Furthermore, die cast parts are able to withstand to a wide range of temperature, making it workable in harsh temperatures and working environments.

High production effeciency – Due to the ability to produce complex parts in net shape with little or no machining processes required, it will greatly reduce the production time. So die casting is considered as one of the most effective process to mass produce non-ferrous metal complex parts.

Green Manufacturing – How long does it takes for plastic to biodegrade? According to scientists, plastics takes at least a few hundreds of years to degrade fully. This means that obsolete plastic products are pilled up in the landfills, polluting our beaches, killing millions of sea animals and causing health hazards to the inhabitants in our neighborhoods. Unlike plastic, die casting parts are primarily made of recycled material. On average, approximately 95% of the metal is recycled from salvaged parts, making it a sustainable material that can be used over and over again without degradation. So die casting is a green manufacturing technique.

Thinner Wall Castings – Compared with sand casting or permanent mold castings, due to the high pressure during the injection process, die casting is able to produce parts with thinner wall thickness. This allows lightweight construction as well as eliminate or reduce the need of secondary operations.

Casting with inserts – The die casting process allows inserts to be cast-in to form certain features such as threaded inserts, heating elements or high strength bearing surfaces.

3. Disadvantages of Die Casting

The main disadvantage to die casting is the very high production cost. Compared to other casting process, both the casting equipments required and the dies and related components are all costly. Therefore, to make die casting cost-effective, a large production volume is preferred. 

Other disadvantages are that the process is limited to high-fluidity metals, and casting weights must be between 30 grams and 10kg. In the standard die casting process the final casting may have a small amount of porosity. This prevents any heat treating or welding, because the heat causes the gas in the pores to expand, which causes micro-cracks inside the part and exfoliation of the surface. Thus a related disadvantage of die casting is that it is only for parts in which softness is acceptable. Parts needing hardening (through hardening or case hardening) and tempering are not feasible for die casting.

4. Types of Die Casting

Hot Chamber Die Casting is the process mainly for alloys like zinc, magnesium or copper. In hot chamber die casting, the injection system is immersed in pool of molten metal hence the name. The furnace is attached to the machine via a feeding system called a gooseneck. As the cycle begins the piston will retracts, which allows the molten metal to fill the “gooseneck” from a port in the injection cylinder. As the plunger move downwards, it seals the port and forces the molten metal through the gooseneck and nozzle into the die. Once the metal solidifies, the plunger will pull upwards. Afterwards, the die will open and the part is ejected. The advantage of this process is its short cycle time and it does not require metal to be transported from a separate furnace. Unfortunately, this die casting process is only suitable for alloys that do not attack the injection cylinder.

Cold Chamber Die Casting is the process primarliy for manufacturing of aluminum die castings. In cold chamber die casting, it uses a ladle to transport the molten metal from the holding furnace into the unheated shot chamber or injection cylinder. This metal is then shot into the die by using a hydraulic piston. The main disadvantage of this process is that it is relatively slower compared to the hot chamber die casting process.

5. Application of  Die Casting

High-pressure die casting can be served in a wide range of industrial applications including:

Recreational Vehicles: We proudly provide superior die casting services for vehicle manufacturers.

Medical: Our die casting company can produce high-quality die castings for medical involved companies. Our expertise encompasses essential medical products such as surgical instruments, hospital equipment, hospital bed gearboxes and peristaltic pump pumps.

Traffic lights: We’re a leading die casting company when it comes to the manufacturing of housings for street and traffic light enclosures, PED boxes and aluminum light enclosures.

Outdoor lighting: You can count on us for expert aluminum die cast services for the manufacturing of outdoor lighting products including walk light housings, bullet light fixtures, coach lights and wall sconce fixtures. Our capabilities also include LED and high efficiency outdoor lighting.

Firearms: we are one of the top die casting companies for the firearms industry, die casting trigger guards, and other shotgun and rifle parts.

Industrial equipment: Our die casting services encompass the manufacturing of numerous types of industrial equipment such as compressor and piston connecting rods, porter cable pump housings, wall mount bearing housings, industrial pumps, air compressors and many others. Regardless of the product, our die castings will offer enhanced strength and performance at an extremely low unit cost.

Telecommunications: We’re an accomplished die cast manufacturer for telecom industry products such as electrical housings, connecting front face plates, waveguides, antenna mounts and RF filters.

So if you have any project on die casting mould, feel free to contact Shine

Email: [email protected]

Phone: +86 157 5766 8880