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Cold Chamber (Aluminum, Zinc Parts) Die Casting Services

Views: 22     Author: Site Editor     Publish Time: 2023-11-28      Origin: Site

Cold Chamber Die Casting 

Cold chamber die casting stands out as the preferred manufacturing technique for metals characterized by elevated melting points. This category commonly encompasses aluminum alloys, zinc alloys, magnesium alloy, brass, and copper. The essential elements for conducting cold chamber die casting involve an external furnace and a ladle for the controlled pouring of molten metal. Renowned for yielding more compact and denser metal castings, cold chamber die-casting methods exemplify a reliable choice.


KYLT serves as your dependable provider for quality cold chamber die casting services. Feel free to reach out to us for further details on our Cold Chamber Die Casting Service offerings or to request a FREE quote today. Service email: cnkylt@aliyun.com


What is cold chamber die casting?

die casting services

Cold chamber die casting is a metal casting process that is used to produce geometrically complex metal parts 8.by forcing molten metal into a metal mold under high pressure. Unlike hot chamber die casting, the cold 7.chamber process involves ladling the molten metal into the shot chamber from an external furnace.


Schematic diagram of working principle of cold chamber die-casting machine


cold chamber die casting



Cold Chamber Die Casting Machine Structure

550T Cold Chamber Die-cast Machine auto ladling machine and sprayer


Cold Chamber Die Casting Machine Structure and Components

A cold chamber die casting machine is used for casting metals with higher melting points, such as aluminum, magnesiu, zamak and copper alloys. Unlike hot chamber die casting machines that are suitable for low melting point metals like zinc, cold chamber machines keep the molten metal in a separate furnace. 

cold chamber die casting machine structure and components

Here is an overview of the structure and components of a typical cold chamber die casting machine:

1. Cold chamber die casting machine's Base:

The base is the foundation of the machine and provides stability. It supports the entire structure and components.

2. Die Casting Unit:

This unit consists of the die, which is a custom-shaped mold into which molten metal is injected to create the desired product.

3. Injection System:

The injection system includes a plunger or piston that pushes molten metal from the furnace into the die. It also consists of a shot chamber and a gooseneck, which connects the shot chamber to the die.

4. Hydraulic System:

Cold chamber die casting machines use a hydraulic system to control the movement of various components. It includes hydraulic cylinders, valves, and a pump to provide the necessary force and control.

5. Clamping Unit:

The clamping unit holds the two halves of the die together during the injection process. It ensures that the die remains closed and under pressure to produce high-quality castings.

6. Ejector System:

After the casting has solidified, the ejector system is used to open the die and remove the finished product. It typically consists of ejector pins and a mechanism for releasing the casting.

7. Furnace:

The furnace in a cold chamber die casting machine holds and melts the metal. It is separate from the machine itself, and a ladle or other transfer mechanism is used to introduce molten metal into the shot chamber.

8. Control Panel:

Modern die casting machines are equipped with a control panel that allows operators to set and monitor various parameters such as temperature, pressure, and cycle times.

9. Cooling System:

A cooling system is incorporated to control the temperature of the die and prevent overheating. This is essential for maintaining the quality of the casting and prolonging the life of the die.

10. Safety Features:

Cold chamber die casting machines are equipped with safety features such as emergency stop buttons, safety guards, and sensors to ensure the well-being of operators and prevent accidents.

These components work in tandem to facilitate the efficient and precise production of metal castings using the cold chamber die casting process.

More information of cold chamber die casting or get a Free quote for your Cold chamber die cast aluminum, zamak alloy parts. Pls. feel free to contact with us: cnkylt@aliyun.com


What materials are commonly used for cold chamber die casting?

The materials commonly used for cold chamber die casting include aluminum, magnesium, and copper alloys.

At KYLT, we always use Aluminum and Zamak alloys. Their detail types and elements are as follows:

 

1. ADC 12, A380, ZAMAK 3, ZAMAK 5 Physical Properties



Aluminum Alloys Physical properties




ADC 12

(Aluminum Alloy)

Density: 2.78 g/cm⊃3;

A380

(Aluminum Alloy)

Density: 2.71 g/cm⊃3;

Melting Point: 580-640°C

Melting Point: 570-640°C

Tensile Strength: 265 MPa

Tensile Strength: 324 MPa

Yield Strength: 230 MPa

Yield Strength: 276 MPa

Elongation at Break: 3-4%

Elongation at Break: 3-4%


Zinc (Zamak) Alloys Physical properties


ZAMAK 3

(Zinc Alloy)

Density: 6.7 g/cm⊃3;

ZAMAK 5

(Zinc Alloy)

Density: 6.7 g/cm⊃3;

Melting Point: 380°C

Melting Point: 380°C

Tensile Strength: 295 MPa

Tensile Strength: 290 MPa

Yield Strength: 225 MPa

Yield Strength: 230 MPa

Elongation at Break: 10%

Elongation at Break: 7%

2. ADC 12, A380, ZAMAK 3, ZAMAK 5 Composition Table


Aluminum Alloys Composition Table




ADC 12

(Aluminum Alloy)

Aluminum (Al): 85.8-88.3%

A380

(Aluminum Alloy)

Aluminum (Al): 85.0%

Silicon (Si): 9.6-12%

Silicon (Si): 7.5-9.5%

Copper (Cu): 1.5-3%

Copper (Cu): 3.0-4.0%

Iron (Fe): 1.3% max

Iron (Fe): 1.3% max

Zinc (Zn): 1.0% max

Zinc (Zn): 3.0-4.0%

Manganese (Mn): 0.5% max

Manganese (Mn): 0.5% max

Magnesium (Mg): 0.3-1.3%

Magnesium (Mg): 0.1% max

Titanium (Ti): 0.2% max

Titanium (Ti): 0.2% max

Other elements: 0.5% max

Other elements: 0.5% max


Zinc (Zamak) Alloys Composition Table


ZAMAK 3

(Zinc Alloy)

Zinc (Zn): 95.8%

ZAMAK 5

(Zinc Alloy)

Zinc (Zn): 95.7%

Aluminum (Al): 3.9-4.3%

Aluminum (Al): 3.9-4.3%

Magnesium (Mg): 0.03-0.06%

Magnesium (Mg): 0.03-0.06%

Copper (Cu): 0.001-0.002%

Copper (Cu): 0.001-0.002%

Lead (Pb): 0.001-0.003%

Lead (Pb): 0.001-0.003%

Cadmium (Cd): 0.002-0.004%

Cadmium (Cd): 0.002-0.004%

Iron (Fe): 0.075% max

Iron (Fe): 0.075% max

Tin (Sn): 0.001-0.003%

Tin (Sn): 0.001-0.003%

Other elements: 0.02% max

Other elements: 0.02% max


Choose KYLT to meet your cold chamber die-casting service with Good quality & Cheap cost

As a die-casting factory & manufacturer for aluminum and zinc alloy components, KYLT benefits from a complete local die-casting mold design/engineering and tool/mold manufacturing industry chain, providing customers with a one-stop complete set of die-casting, machining, surface treatment, assembly, and export services. KYLT has over 20 years of experience in die casting, exporting die castings to the United States, the United Kingdom, Germany, Spain, Japan, and more. KYLT is a reliable source of your cold chamber die-casting services. Service email: cnkylt@aliyun.com


Advantages of Cold Chamber Die Casting

Cold chamber die casting stands out as a pragmatic and cost-effective manufacturing process capable of producing a diverse array of shapes and components in comparison to alternative methods. This process is well-suited for crafting parts with extended service life, and it can be tailored to enhance the visual aesthetics of the surrounding components. The direct advantages offered by the cold chamber die casting process encompasses:

A. Enhanced Strength and Durability

One of the primary advantages of this method is the superior strength and durability of the castings produced. The controlled cooling process results in a fine-grained structure, enhancing the mechanical properties of the components.

B. Complex Geometries

Cold Chamber Die Casting allows for the production of complex and detailed geometries that may be challenging with other manufacturing methods. This opens the door to designing intricate parts with precision.

C. High Production Rates

Manufacturers benefit from the high production rates achievable with Cold Chamber Die Casting. The rapid cycle times make it an efficient choice for large-scale production without compromising on quality.

D. Precision and Stability in Dimensions

This method creates sturdy and dimensionally stable parts while maintaining tight tolerances and resistance to heat.

E. Simpler assembly 

Cold chamber die castings can be equipped with built-in fastening components such as bosses and bolts. The hole can be taken from the core to the size of the tapping drill bit, or external threads can be cast for easy assembly. Meanwhile, cold chamber die casting can integrate multiple product structures into one. For example, Tesla replaces the traditional sheet metal stamping and welding process with aluminum alloy die-casting body technology.

 Get a Free quotation for your Cold chamber die cast aluminum, zamak alloy parts. Pls. feel free to contact with us: cnkylt@aliyun.com


Cold Chamber Die Casting Process

The cold chamber die casting process involves the following steps:

A. Molten Metal & Ladling

The die casting machine's injection system is located outside the die casting machine's chamber. The molten metal is poured into the cold chamber, where it is then fed into the die casting machine's chamber.

B. Injection and Cooling/Solidification

The die casting machine's plunger then forces the molten metal into the die cavity at high pressure, ensuring that the metal fills the entire cavity and solidifies quickly.

C. Ejection of the Casting

Once the casting has solidified, it is ejected from the die, ready for further processing or application. This efficient ejection process contributes to the overall speed and effectiveness of Cold Chamber Die Casting.

D. Die Casting Parts Treatment

The casting is then removed from the die and any excess material is trimmed off.


Full automatic & Manual Cold Chamber Die Casting Manufacturing Process

There are both automatic and manual variations of the cold chamber die casting process.


Automatic Cold Chamber Die Casting Process:

Cold chamber die casting machine equipped with auto-ladling machine, auto-spraying machine, auto die casting parts pick-up machine to create a full-auto die casting unit, all machines' behavior controlled by PLC.

1. Melting and Injection Unit:

  • Automatic cold chamber die casting machines have an integrated melting and injection unit.

  • Metal, usually aluminum or zinc alloys, is melted in a separate furnace.

  • The molten metal is then automatically transferred to the cold chamber of the die casting machine by auto ladling machine.

2. Die Preparation:

The die (mold) is prepared with the desired cavity shape for the component to be cast.

3. Clamping of cold chamber die casting machine:

The die halves are closed and clamped together under high pressure.

4. Injection of cold chamber die casting:

The automatic machine injects the molten metal into the die cavity at high pressure, ensuring the material fills all intricate details of the mold.

4. Cooling:

After injection, the molten metal is allowed to cool and solidify in the die.

5. Ejection of die casting parts:

  • Once solidified, the newly formed part is ejected automatically from the die.

  • Auto die casting parts pick-up machine takes the die casting parts out from the mold.

  • Auto spraying machine sprays mold release agency to mold cavities to lubricate and cool the mold cavities.

6. Die casting repetition:

The process is repeated for the production of multiple components in a highly efficient and automated manner.

KYLT has full automatic cold chamber die cast machines to produce all kinds of aluminum, zamak alloy diecast parts. Free quotation service, please email us: cnkylt@aliyun.com


Full automatic cold chamber die casting working process video:


Manual Cold Chamber Die Casting Process:

The manual cold chamber die casting process usually produces die casting parts with insert parts or casting parts with special structures. In the manual casting operation process, some processes can reach automatic working, such as pouring molten metal into the cold chamber, lubricating the mold, etc. Worker sets insert parts to mold cavities and manually pick up the die casting parts from mold processes.

1. Melting:

In manual cold chamber die casting, operators manually melt the metal, typically in a separate furnace.

2. Transfer to Cold Chamber:

The molten metal is manually transferred to the cold chamber of the die casting machine by ladle.

3. Die Preparation:

The die is prepared manually for the specific part to be cast.

4. Clamping:

Operators manually close and clamp the die halves together.

5. Injection:

The molten metal is manually injected into the die under pressure.

6. Cooling:

The cooling process is allowed to occur naturally or may be assisted by cooling systems.

7. Ejection:

Once the metal solidifies, operators manually eject the casting from the die.

8. Repetition:

The manual process is repeated for each casting, making it a more labor-intensive and slower method compared to automatic cold chamber die casting.

While automatic processes offer higher efficiency and consistency, manual processes may be preferred for smaller-scale productions or when specific expertise is required in handling intricate parts. The choice between automatic and manual cold chamber die casting depends on the production requirements and the complexity of the components.

KYLT provides semi-automatic or manual cold chamber die casting servcies as per different casting requirement.  Free quotation for your Aluminum, zamak alloy diecast parts, please email us: cnkylt@aliyun.com


Manual die casting working process video:



The Movement of Die Casting Mold in Cold Chamber Die Casting Process

The operating sequence of the cold-chamber die casting mold working process (PDF file download)

The Movement of Die Casting Mold in Cold Chamber Die Casting Process.pdf

1. Diagram of Cold chamber die casting mold. Cold chamber die casting mold structure. Mold close, ready for injection.

cold chamber die casting mold structure - ready for die casting

2. Molten metal (magnesium, zinc/zamak alloy) be injected into die casting mold cavity by die casting machine plunger.

cold chamber die casting injection

3. Die casting die open. After injection, insert core or slider move out, and movable die open.

die open after casting

4. Eject plate & pins be pushed by Ejecting oil cylinder, ejection pins eject die casting part out from mold cavity. Die casting part be picked up by manual or auto pick-up machine.

eject die casting part out from mold cavity

5. Mold closing, ejection pins, insert core or slider back to position. Ready for next die casting cycle.

die casting mold close for next injection cycle



KYLT Aluminum, Zamak alloy diecast services, please email us: cnkylt@aliyun.com


KYLT Cold chamber die casting machines and Machining equipments

KYLT uses a wide range of tonnage cold chamber die-casting machines and machining equipment to produce high-quality die casting parts. Our cold chamber die casting machine options and equipment include:

Tonnage Die Casting & Machining Equipment Qty. Unit Materials

1200T

  Cold Chamber Die Casting Machine

1

set

Aluminum, Zinc

1100T

  Cold Chamber Die Casting Machine

1

set

Aluminum, Zinc

850T

  Cold Chamber Die Casting Machine

1

set

Aluminum, Zinc

630T

  Cold Chamber Die Casting Machine

1

set

Aluminum, Zinc

500T

  Cold Chamber Die Casting Machine

1

set

Aluminum, Zinc

300T

  Cold Chamber Die Casting Machine

2

set

Aluminum, Zinc

200T

  Cold Chamber Die Casting Machine

2

set

Aluminum, Zinc

  CNC Machines

5

set



  NC Lathe

3

set



  Driller

6

set



  Milling Machine

1

set



  Hydraulic Press Machine

1

set



  Shot Blasting Machine

1

set



  Vibration grinding Machine

1

set



Sanding & Polishing Machines

5

set


KYLT provides "One-stop full services" for your Aluminum, Zamak die casting projects, please email us: cnkylt@aliyun.com


Cold chamber die casting application - Aluminum parts & Zinc(Zamak) parts show:


Forklift reflector holder

Zamak part for Forklift reflector

Zamak die cast bus inner door handle

Zinc Bus door handles


Zinc chair support

Zinc connector for chair

Aluminum Zinc Die Casting

Aluminum die casting parts - motor cover

Surface Finishes of Die Casting Parts

Powder coated aluminum die casting parts


die casting

Cold chamber aluminum die casting

aluminum die casting parts by CNC turning

Aluminum die cast part by CNC turning

aluminum die casting parts with CNC milling

CNC lathe machined aluminum die cast parts

aluminum die casting parts with blackening treatment Aluminum electric box for Electric vehicle
aluminum die casting motor housing

Aluminum die casting motor housing

aluminum die cast natural gas meter box

Aluminum die cast natural gas meter box

aluminum chair parts with shot blasting

Aluminum chair parts with shot blasting

Aluminum die casting motor housing

Aluminum motor housing with powder coating

Machined aluminum die casting part with powder coating

Aluminum cast chain shell with powder coating

aluminum die casting cover with radiation fins

Aluminum radiator with painting

aluminum die cast auto parts

Aluminum alloy cleaning machine pump body with CNC machining

aluminum die casting electric cutter shield

Electric cutting machine Aluminum protective cover

Aluminum die casting electrical box Aluminum Electrical box
aluminum die casting LED lamp radiator

LED light Aluminum cooling base


assembly

Finished aluminum zinc die casting parts assembly service

Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.



KYLT Cold chamber die casting & maching services, Assembly and installation services


Cold chamber die casting & machining services:

1. Aluminum and Zinc metal alloy product analysis before mold making.

2. Aluminum and Zinc die casting molds making

3. Die casting molds test and die casting parts samples for end-users' inspection

4. Drilling, tapping, CNC machining (CNC milling, CNC turning)

5. Various surface coatings and treatments: painting, spraying, shot blasting, polishing, vibration grinding, electrophoresis, etc

die casting surface finishes

Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.


Assembly and installation services:

For projects with specific assembly and installation requirements, KYLT Die Casting works closely with customers to explore assembly and installation solutions. KYLT can assist in processing the following requests:

1. Production and procurement require the use of inserts specified in the drawings during the die-casting process.

2. Die cast parts shall be processed with internal and external threads according to the drawing requirements.

3. Perform precision CNC milling and CNC turning machining according to the drawing requirements.

4. Install pins and/or spiral inserts after machining.

5. Assemble finished and semi-finished products according to customer requirements. Supporting the production of various injection molded parts, stamped parts, sheet metal parts, CNC rapid prototyping, welded parts, etc.


Cold chamber die casting aluminum & zinc part machining & assemblying video:

Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.


What is the difference between cold chamber and hot chamber die casting?

The main difference between cold chamber and hot chamber die casting lies in the method of molten metal delivery. In hot chamber die casting, the metal is melted in the casting machine's holding furnace and then delivered into the die casting mold using a piston. In cold chamber die casting, the molten metal is ladled into a separate chamber and then forced into the mold using a hydraulic piston.


Schematic photo of cold chamber die-casting machine and hot chamber die-casting machine

hot & cold chamber die casting


Physical picture of cold chamber die-casting machine and hot chamber die-casting machine

Hot Cold Chamber Die Casting


Discover the Difference of KYLT Cold Chamber Die Casting Manufacturing Services

At KYLT, every component we produce is customized and engineered according to the exact specifications of the customer. In the engineering phase, we will provide final recommendations for the finished products of the die-casting process based on the actual assembly and usage requirements of the customer's products. The output of each component we produce may range from a few hundred to several hundred thousand.

Contact us to learn more about our customized one-stop cold chamber die-casting service; Please email: cnkylt@aliyun.com Or request an immediate free quote.






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