Customized Aluminum Die Casting Part Gravity Casting

Die casting is a metal casting process that utilizes the inner cavity of the mold to apply high pressure to the melted metal. Molds are usually made from alloys with higher strength, and this process is somewhat similar to injection molding. Most die-casting castings are free of iron, such as zinc, copper, aluminum, magnesium, lead, tin, and lead-tin alloys and their alloys. Depending on the type of die-casting, it is necessary to use a cold chamber die-casting machine or a hot chamber die-casting machine.

The cost of casting equipment and molds is high, so the die-casting process is generally only used for mass production of a large number of products. Manufacturing die-casting components is relatively easy, which usually only requires four main steps and has a low incremental cost per unit. Die casting is particularly suitable for manufacturing a large number of small and medium-sized castings, therefore it is the most widely used among various casting processes. Compared with other casting techniques, the surface of die casting is smoother and has higher dimensional consistency.

Several improved processes have emerged on the basis of traditional die-casting processes, including the non porous die-casting process that reduces casting defects and eliminates porosity. Mainly used for processing zinc, a direct injection process that can reduce waste and increase yield. There are also new die-casting processes such as precision and dense die-casting technology invented by General Dynamics and semi solid die-casting.

Die-casting machines can be mainly divided into two different types: hot chamber die-casting machines and cold chamber die-casting machines. The difference lies in how much force they can withstand, with a typical pressure range of 400 to 4000 tons.

Hot chamber die casting

Hot chamber die-casting, sometimes also known as gooseneck die-casting, has a molten liquid or semi liquid metal pool that fills the mold under pressure. At the beginning of the cycle, the piston of the machine is in a contracting state, and the molten metal can fill the gooseneck area. Pneumatic or hydraulic pistons squeeze metal and fill it into the mold. The advantages of this system include fast cycling speed (approximately 15 cycles can be completed per minute), easy automation, and the convenience of melting the metal. Disadvantages include the inability to die-cast metals with high melting points, as well as the inability to die-cast aluminum, as aluminum can remove iron from the melting pool. Therefore, hot chamber die-casting machines are usually used for alloys of zinc, tin, and lead. Moreover, hot chamber die-casting is difficult to use for large castings, and usually this process involves die-casting small castings.

Cold Chamber Die Casting

When die-casting cannot be used for metals in the hot chamber die-casting process, cold chamber die-casting can be used, including aluminum, magnesium, copper, and zinc alloys with high aluminum content. In this process, the metal needs to be melted first in a separate crucible. Then a certain amount of molten metal is transferred to an unheated injection chamber or nozzle. These metals are injected into the mold through hydraulic or mechanical pressure. Due to the need to transfer molten metal into the cold chamber, the biggest drawback of this process is the long cycle time. Cold chamber die-casting machines can also be divided into vertical and horizontal types. Vertical die-casting machines are usually small machines, while horizontal die-casting machines come in various models.

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