What is aluminum die casting parts?

Why called aluminum die casting parts

Aluminum die-casting is a metal casting process characterized by applying a high pressure to a molten liquid metal aluminum alloy by a die casting machine, and injecting it into a designed mold cavity at a high speed to cast aluminum alloy parts of a shape and size limited by the mold.

The main steps of the process are as follows:

First step,melting the aluminum metal, usually using an electric furnace or a coke oven to heat the molten aluminum ingot to a liquid state, maintaining the temperature at about 600-700℃。

Step two, when the metal aluminum is melted, the corresponding die-casting mold is synchronously assembled on the die-casting machine, and pre-heating is performed, and the die-casting machine is adjusted to ensure the ideal working state.

Step three, the molten aluminum metal is poured into the compression chamber of the press, and then the injection system of the press presses the poured aluminum water into the cavity of the mold through the piston at a high speed, and the specific path is the sleeve passing through the compression chamber first. The barrel then enters the flow path and ingate of the mold and then fills the entire cavity.

Step four. After the casting is taken out, the aluminum water fills the entire mold cavity, and then starts to cool and solidify in a very short time, and the mold is opened in a set time to take out the casting.

Step five. After the casting is taken out, spray the mold (lubricate the mold) and close the mold to prepare for the next new die casting cycle. Molds are usually machined from higher strength alloys, some of which are similar to injection molding.

Such parts are produced with this process usually called aluminum die casting parts.

What's the advantages of aluminum die casting parts?

• Good lightweight rate

• Sufficient dimensional stability for complex configuration and thin walls

• Good corrosion resistance

• Excellent mechanical properties

• Great thermal and electrical conductivity

• Maintain strength at high temperatures.

What's the casting equipment for aluminum die casting parts？

The mechanical equipment for manufacturing aluminum die castings is called die casting machine.

The general die casting machine can be divided into two types: hot chamber die casting machine and cold chamber die casting machine, but the equipment used for aluminum die casting is mainly cold chamber die casting machine.

Cold chamber die casting machine refers to a casting method in which the injection chamber and the injection punch are not immersed in the molten metal, and the quantitative molten metal is poured into the injection chamber and then injected, mainly for aluminum, Magnesium, copper and zinc alloys with a high aluminum content.

In the process of cold chamber die casting, the metal needs to be melted first in a separate crucible. A certain amount of molten metal is then transferred to an unheated injection chamber or nozzle. These metals are injected into the mold by hydraulic or mechanical pressure. Due to the need to transfer molten metal into the cold chamber.the biggest

disadvantage of this cold chamber die casting is the long cycle time.

Cold chamber die casting machines are also available in vertical and horizontal types. Vertical die casting machines are usually small machines, while horizontal die casting machines are available in various models.

How to design a premium die casting parts?

There are a number of geometric features to be considered when creating a parametric model of a die casting part,good design can eliminate the potential problems,like porocity , thermal balancing, cost-effective, die life,etc.

• Draft, is the amount of slope or taper given to cores or other parts of the die cavity to allow for easy ejection of the casting from the die. All die cast surfaces that are parallel to the opening direction of the die require draft for the proper ejection of the casting from the die. Die castings that feature proper draft are easier to remove from the die and result in high-quality surfaces and more precise finished product.

• Fillet, is the curved juncture of two surfaces that would have otherwise met at a sharp corner or edge. Simply, fillets can be added to a die casting to remove undesirable edges and corners.

• Parting line, represents the point at which two different sides of a mold come together. The location of the parting line defines which side of the die is the cover and which is the ejector.

• Bosses ,are added to die castings to serve as stand-offs and mounting points for parts that will need to be mounted. For maximum integrity and strength of the die casting, bosses must have universal wall thickness.

• Ribs ,are added to a die casting to provide added support for designs that require maximum strength without increased wall thickness.

• Holes and windows, require special consideration when die casting because the perimeters of these features will grip to the die steel during solidification. To counteract this effect, generous draft should be added to hole and window features.

• Uniform walls, the uniformed walls of the casting can avoid the porocity generated. As the melted aluminum will get a nearly equal solidification time while filling into the cavities.

• Application:

－ Automotive

－ Transmission device

－ Lighting

－ Electronic enclosure

－ Valve

－ Mechanic equipment

－ Construction

Features of Reigstone die casting

Quite compact

Enough compact can make the part stronger on the aspect of mechanical properties.Instead of your other idea maybe with steel or other heavy metals, save cost on material and transporting.

Smooth surface

Smooth and flat surface makes appearance looks beautiful, and good texture.

Class 2-3 for die casting surface we can guarantee, following NADCA standard.

Precise dimension tolerance

Our as-cast usually can achieve CT5-CT4 grade, obviously it can reduce some machining processes and cost with such accurate casting dimension tolerance.

No or very few small porosities

It can help you to think various processes to develop project, when you don’t need to consider leaking,lighten your load and save your extra cost.

Reigstone die Casting service

We dedicated in the manufacturing of aluminum die casting parts since 2002,more information about our service,please visit our click here https://www.reigstone.com/Service/