Die Casting
JC Casting is a global manufacturer of investment casting and multi-slide die casting precision components. Our engineers can help design solutions and parts specifically for mass production. Our die casting machines’ capability range from 150 up to 2,000 metric tons. The finished die casting parts from 10 grams to more than 100 kgs with assembly. JC Casting customized die casting parts and components are used in a wide range of industries. Including automotive, food dairy, machinery, design solutions, medical, plumbing, watering, mining, petrochemical, electrical, energy, aerospace, submarine.
For die casting parts with requirements of esthetical, functional, or protective coatings. We offer surface finishing. Including powder coating, e-coating, shot blasting, chrome plating, and bright finish.
What Is Die Casting?
Die casting is an automated metal casting process. In processing, The liquid melt is pressed into a mold under high pressure (200 to 1200 bar) and at a high filling speed (up to 500 km/h). The mold cavity is created using two hardened tool steel molds that are machined during processing. It works like injection molds. This casting process is particularly suitable for the series and mass production.
Usually, non-ferrous metals alloys with a low melting point are used. especially zinc, copper, aluminum, magnesium, lead, tin, tin-based alloys.
According to the type of metal being cast, the Hot Chamber Die Casting Method and Cold Chamber Die Casting Method
How are Die Castings Made?
To produce tens of thousands of castings at high speed, the steel mold must be made in at least two sections to allow the castings to be removed. These parts are firmly mounted in the machine and are arranged so that one is stationary (fixed die half). The other one is movable (syringe half-mold). To begin the casting cycle, the two mold halves are clamped together by a die-casting machine. Molten metal is injected into the mold cavity and rapidly solidified. The mold half is opened and the casting is ejected. Die-casting molds can be simple or complicated, with moveable slides, cores, or other parts. This is depending on the complexity of the casting.
Until now, the die casting cycle has been the fastest cycle to produce precision nonferrous metal parts. This is in stark contrast to sand casting. It requires new sand molds for each casting. Although the permanent mold process uses iron or steel molds instead of sand. It is much slower and less precise than die castings.
Applications
Automotive and recreational vehicles: chassis to the counter mounts,
Medicine: Medical instruments and hospital equipment call for incredibly precise and accurate components.
Telecommunications and Lighting: These industries require electrical enclosures to provide essential weatherproofing tools used in many environments. We make custom enclosures for any application.
Industrial equipment: custom components for industrial equipment. housings, pumps,air compressors.
Die Cast Process
In die casting, there are two different ways of manufacturing components: hot chamber and cold chamber die casting. In both manufacturing processes
Hot Chamber Die Casting Method
This process is used for low-melting alloys. Such as zinc, lead, tin, magnesium alloys. One feature of hot chamber die casting machines is that the casting chamber is constantly in contact with the liquid alloy. The melt passes through a valve into the casting chamber. At there, it is pressed at high speed into the closed die casting mold by the piston. Hot-chamber die casting is a great option for alloys that do not readily attack and erode metal pots, cylinders, and plungers.
Cold Chamber Die Casting Method
This process is better suited for metals with high melting points such as aluminum, copper.
In the cold chamber die casting process, metal is liquefied. Then ladled into a cold chamber. At there, a hydraulically operated plunger pushes the metal into the mold.
After the alloy has been pressed into the mold in both processes, the component solidifies under strong pressure. Then remove from the mold. t can be further processed if necessary.
Advantages of Die Casting
Efficient, economical are the best advantages for die casting. Die-cast parts typically have a long service life. Generally, they are designed to complement the surrounding part’s visual appeal. More advantages by using die-cast parts. Including:
Simple or complex shapes, Thin-wall thicknessMonolithic – combine multiple functions in oneThin wall thickness – up to 0.040 inches for small castingsLightweight – light alloys are usedCorrosion resistance – surfaces are smoother than other casting typesHigh-speed production– Die castings can be produced into complex shapes with closer tolerances than most mass production processes. Most of the time, little to no machining is neededDimensional accuracy and stability— Die casting produces durable and dimensionally stable parts while maintaining close tolerances.
Die Casting Material Types
| Material | Tensile Strength (Mpa) | Thermal Conductivity (W/mK) | Features |
|---|---|---|---|
| Aluminum A380 | 325 | 96 | Best combination of mechanical, casting, and the thermal properties.Excellent fluidity, pressure tightness, and resistance to hot cracking.Widely used for engine brackets, hand tools, electronic equipment chassis, gearbox cases, and household furniture. |
| Aluminum A360 | 317 | 113 | Excellent pressure tightness and fluidity.High corrosion resistance.High strength in elevated temperatures. |
| Aluminum 413 | 295 | 121 | Good combination of casting, mechanical, and thermal properties.Excellent fluidity, pressure tightness, and resistance to hot cracking. |
| Aluminum 383 | 310 | 96 | Often used for highly intricate components.Good corrosion resistance, lightweight. Good combination of casting, mechanical, and dimension stability. |
| Aluminum B390 | 317 | 134 | High hardness and good wear resistance.Suitable for internal combustion engine pistons, cylinder bodies for compressors, and brakes. |
| Aluminum A413 | 290 | 121 | Excellent pressure tightness.Good choice for hydraulic cylinders. Suitable for die casting intricate components. |
| ZAMAK 2 | 359 | 105 | Excellent damping capacity and vibration attenuation.Superior to other Zamak alloys with creep performance.High strength and hardness levels after long-term aging |
| ZAMAK 3 | 283 | 113 | Great balance of physical and mechanical properties.Excellent finishing characteristics for plating, painting, and chromate treatments.Good castability and long-term dimensional stability.Good damping capacity and vibration attenuation. |
| ZAMAK 5 | 328 | 109 | Has a higher copper content than Zamak 3, which results in higher strength.Has less ductility than Zamak 3. More readily plated, finished, and machined than Zamak 3. |
| ZA 8 | 374 | 115 | Ideal for decorative application.Excellent finishing and plating characteristics.Good performance of strength, hardness, and creep properties. |
Secondary Operations of Die Casting
- High precision CNC machining, milling, drilling, tapping, e-coating, anodizing
- Painting, sanding, shot blasting, powder coating, chrome plating
Typical Die Casting Parts
AL Mg,Zn