Pressure Die Casting Aluminum Parts

Aluminum Die Casting is a process of injection of Aluminum or Aluminum Alloys under pressure, which produces parts in high volume at low costs.

There are two processes of Aluminum die casting: hot chamber and cold chamber.

A complete cycle can vary from one second for small components to minutes for a casting of large part, making aluminum die casting the fastest technique available for producing precise aluminum & aluminum alloy parts.

The main disadvantage to die casting is the very high capital cost. Both the casting equipment required and the dies and related components are very costly, as compared to most other casting processes. Therefore, to make die casting an economic process, a large production volume is needed. Other disadvantages are that the process is limited to high-fluidity metals, and casting weights must be between 30 grams (1 oz) and 10 kg (20 lb). In the standard die casting process the final casting will 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.[4] 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 cast in dies.

Inspection

After the shakeout of the casting it is inspected for defects. The most common defects are misruns and cold shuts. These defects can be caused by cold dies, low metal temperature, dirty metal, lack of venting, or too much lubricant. Other possible defects are gas porosity, shrinkage porosity, hot tears, and flow marks. Flow marks are marks left on the surface of the casting due to poor gating, sharp corners, or excessive lubricant

Main particulars

	MAIN PARTICULARS
Material for mould	H13,DIEVAR,QDN,8407,2344V,TQ1,2343,SKD61, 45#steel,etc.
Heat treatment for mould	Hardened, HRC50~55
Mould features	Advanced design, Logical structure, High precision, Qualified materials, Long lifetime, Short delivery time.
Material for product	Aluminum & Aluminum alloy A356, A360, A380, A390, ADC-12,ADC10, Zinc & Zinc alloy. ZA-3,ZA-5,ZA-8
Standard	ASTM, ASME, DIN, JIS, ISO, BS, API, EN
Certificate	ISO9001, BV
Dimension	As per drawing, as large as we can
Processing	Step1: Die Casting/sand casting/gravity casting Step2: CNC turning, CNC turning and milling compound processing, 3/4/5 axis Cnc Milling, drilling, wire-cutting, EDM, grinding etc.
Finishing surface	Machined surface with tectyl891, blasting and painting(Hempel, Inter, Sigma, Jotun), anodize, polishing
Marking	as per clients` requirements
Inspection	material, construction, dimension, heat treatment, hardness, NDT
Quality	ISO9001, BV, PPAP control production
Lead time	5 days for sample, consult with customer for mass production
Delivery	Express for sample, ocean shipping/air for mass production
Our Capabilities	CNC Machining, CNC center machining, drilling, milling, turning, grinding, tapping, forging, stamping
Engineering&manufacturing services	R&D process, tooling and gauging design, product design Integrated CAD/CAM system, test and measuring
Others	Recyclable, in line with environmental requirements and standards, and reliable

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