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WHAT IS DIE CASTING

Die casting is the manufacturing process of pouring or pressing molten metal into a steel mold. Molds (also called tools or dies) are made of steel and are specifically designed for each project. Yifei can provide custom die casting service for our customers. Aluminum, zinc, and magnesium are the most commonly used die casting alloys.

The ability to produce high-detail and high-precision parts makes pressure die casting being a suitable choice for mass-produced products. If we observe the surroundings, we will find that we are almost surrounded by various products produced by the pressure die casting process. Such as faucets, door handles, wheels, frames, etc.

Types of Machines for Die Casting

1. Hot Chamber Die Casting
Hot chamber die casting machines are mainly used for melting low-temperature alloys such as zinc, tin, and lead. If the molten alloy with a high melting point is easy to damage the pump that is in direct contact with the molten metal. The metal is packed in an open holding pot, which is placed in an oven, where it melts to the desired temperature.

The molten metal alloy then flows into the shot blasting chamber through the inlet and plunger, which is hydraulically driven to force the molten metal into the mold through the gooseneck channel. The injection pressure of the zinc hot chamber die casting machine is generally between 1000 and 5000 psi.

After the molten metal is injected into the mold cavity, the plunger maintains pressure while the casting is solidified. After curing, the hydraulic system retracts the plunger and the part can be ejected through the clamping unit.

The first half of the die casting mold (called the cover mold) is mounted on a fixed platen and aligned with the gooseneck channel. The second half of the die casting mold (called the ejector mold) is mounted on a movable platen that can slide along the tie rod.

The hydraulic clamping device drives the clamping rod, which pushes the pressure plate towards the cover die and applies enough pressure to keep it closed when the molten metal is injected. After the metal solidifies in the cavity, the clamping device releases the mold halves and at the same time, the ejection system pushes the casting out of the open cavity. The die casting mold can then be closed for the next injection.
2. Cold Chamber Die Casting
Cold chamber die casting machines are mainly used to melt alloys with high temperatures. Because they damage the pumping system, they cannot be cast in hot chamber machines. Such alloys include aluminum, brass, and magnesium.

The molten metal is still contained in the open holding tank, which is placed in the furnace, where it is melted to the desired temperature. Molten metal is poured from the ladle into the shot blasting chamber through the pouring hole.

The injection system in aluminum cold chamber machine is similar to the injection system in hot chamber machines, but is generally horizontal and does not include gooseneck channels. The typical injection pressure for cold chamber die casting machines is between 2,000 and 20,000 psi.

The hydraulically driven plunger presses the molten metal through the shot blasting chamber and into the injection sleeve in the mold. After the molten metal is injected into the mold cavity, the plunger stays forward and maintains pressure while the casting is solidified.

After curing, the hydraulic system retracts the plunger and the part can be ejected through the clamping unit. The clamping unit and installation of the mold are the same as the hot chamber die casting machine.

Die Casting Alloys

Aluminum Alloys
Aluminum die castings are lightweight and can withstand the highest operating temperature of all die casting alloys. One of the most significant advantages of aluminum die casting parts is that, compared with other die casting alloys, it can produce lighter high pressure die casting products with more surface treatment options.

As manufacturing costs increase, aluminum die castings are most commonly found in automotive parts and gears. Aluminum die castings are also used in handheld devices, heavy-duty electronic connectors, telecommunications and computing industries.
Zinc die casting is a relatively easy process because it can maintain higher strength at room temperature, but it can be alloyed with die cast aluminum alloys to further improve these qualities. Zinc alloy has a lower melting point than aluminum, so it is suitable for hot chamber die casting machine.

The high strength and hardness of zinc alloy make it suitable for many solutions. Compared with pressing, machining, and stamping parts, zinc alloy die casting is the easiest alloy to die cast and provides a better choice in terms of cost. Zinc alloys can be used in consumer electronics, computers, telecommunications, the automotive industry, and mesh zinc housings. This alloy can be fully recycled and is a low-cost raw material.
Magnesium Alloys
Although magnesium is a relatively light alloy, it still has a high strength to weight ratio, about 1.8 grams per cubic centimeter. It can be used for die casting operations that require thin-walled structures and high precision.

Magnesium die casting alloy is 75% lighter than steel and 33% lighter than aluminum alloy, providing integration of components and functions. Magnesium alloy die castings have high dimensional stability, which improves the fit and finish. The magnesium alloy can be fully recycled and has excellent EMI/RFI shielding performance.

Services Yifei Can Offer

Aluminum Die Casting
Our custom aluminum die casting services have been helping engineers, product designers and architects bring their designs to life with state of the art part designs and reliable quality. 
Zinc Die Casting
We specialize in delivering advanced miniature customized 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, Yifei has extensive knowledge and expertise to provide the best magnesium die casting customization parts.
Die Casting Design
The key element of the die casting design process is the development of custom prototypes. We provide complete die casting mold design services to ensure that the final product is very suitable for your specific application.
CNC Machining
Yifei 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 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.

Die Casting Application

Currently, various manufacturing industries rely on one or more types of die casting processes. Die casting service 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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If you would like to have a question then get in touch today, we are ready to assist 24/7. We welcome your cooperation and we will develop with you.

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NINGBO YIFEI MACHINERY PARTS CO., LTD.

We are an exported-oriented enterprises specialized in casting & forging parts.

 
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