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Die casting

  • Q What metal is a die cast made of?

    A
    Aluminum: Aluminum is one of the most popular materials for die casting due to its low density, high strength, and excellent corrosion resistance.
    Zinc/Zamak: Zinc is a highly versatile metal that can be easily cast into complex shapes with tight tolerances. It is also relatively inexpensive compared to other metals.
    Magnesium: Magnesium is a lightweight metal that offers excellent strength-to-weight ratio and high thermal conductivity. It is often used in applications where weight reduction is a critical factor.
    Copper-based alloys: Copper-based alloys are known for their high strength, corrosion resistance, and good electrical conductivity. They are commonly used in electrical and automotive applications.
    The specific choice of metal will depend on the requirements of the application and the desired properties of the finished part. In any case, the metal must be able to maintain its integrity at high temperatures and have good fluidity to enable complete filling of the mold.

  • Q What steel is used for die casting?

    A The type of steel used for die casting depends on the specific application and requirements of the part being produced. Generally, tool steels such as H13, D2, and P20 are commonly used for die casting because of their high hardness, toughness, wear resistance, and thermal conductivity. These properties help to ensure that the mold can withstand the high pressures and temperatures involved in the die casting process, while also providing a long service life. Additionally, some manufacturers may use specialty alloys or coatings to further enhance the performance and durability of the die casting molds.

  • Q What tools are used in die casting?

    A
    Die cast tooling also named die casting dies and die casting molds. The toolings (molds) used in die casting are typically made from hardened tool steel and designed to withstand the high temperatures and pressures involved in the process. There are two main types of dies used in die casting:
    1. Single cavity die: This type of die creates only one part per cycle, making it suitable for lower volume production runs or for parts that require a high degree of complexity.
    2. Multiple cavity die: This type of die has multiple cavities, which allows for the simultaneous production of several identical parts in each cycle. This is more efficient and cost-effective for high-volume production runs.
    The molds are created using computer-aided design (CAD) software and precision machining tools. The mold consists of two halves, called the cover and ejector, that fit together and form a cavity into which the molten metal is injected. The cover half of the mold contains the sprue, runner, and gate, which guide the molten metal into the cavity of the mold. The ejector half of the mold contains pins or sleeves that help to eject the finished parts from the mold once they have cooled and solidified.
    The molds can also be designed with additional features such as slides, cores, and inserts, which allow for the production of more complex parts with internal geometry or undercuts. The molds need to be carefully maintained and cleaned regularly to ensure consistent quality and accuracy of the final part.
    When dealing with the die casting parts, we have Machining toolings, Trimming toolings etc.

  • Q What metal is best for die casting?

    A Aluminum, zinc, magnesium, and copper-based alloys are the common metals used for die casting. The choice of metal for die casting depends on the specific application and requirements of the part being produced. Generally, metals that are easy to melt and have good fluidity at high temperatures are ideal for die casting. Of these, aluminum is one of the most popular choices for die casting due to its low density, high strength, and excellent corrosion resistance. However, the selection of the best metal for die casting ultimately depends on the desired properties and characteristics of the finished part.

  • Q What metal Cannot die cast?

    A Ferrous metals, such as carbon steel & stainless steel, that have properties that make them difficult or impossible to die-cast. For example, some metals with very high melting points, such as tungsten, molybdenum, steel iron etcs are not typically die-cast because of the extreme temperatures required for casting.  Highly reactive metals such as magnesium and titanium are difficult to die-cast due to their flammability and reactivity with the atmosphere. Ultimately, the decision to use a particular type of metal for die-casting will depend on factors such as the specific application, production requirements, and cost considerations.

  • Q Why is it called die casting?

    A Die casting is called so because it involves the use of a metal die or mold into which molten metal is injected, under high pressure, to create complex shapes with high accuracy and consistency. The term "die" refers to the metal molds used in the process, which are typically made from hardened steel by CNC machining & EMD and designed to withstand the high pressures and temperatures involved in the casting process. The molten metal is forced into the die cavity, where it quickly solidifies and takes on the shape of the mold. This process is known as "casting," hence the name "die casting."

  • Q What is the most common die casting?

    A
    Aluminum, Zinc/ZAMAK, Lead/PB, Magnesium, Copper/Brass are five commonly used metals for diecasting.

  • Q What are the two basic methods of die casting called?

    A
    Hot chamber die casting and Cold chamber die casting are two kinds of basic die casting methods.
    In hot chamber die casting, also known as gooseneck or direct chamber die casting, the metal is melted in a furnace and then transferred to the die casting machine via a gooseneck tube. The gooseneck is immersed in the molten metal, which eliminates the need for a separate melting furnace or holding pot. This method is primarily used for alloys with low melting points, such as zinc, tin, and lead.
    In cold chamber die casting, also known as plunger or indirect chamber die casting, the molten metal is poured into a separate chamber or shot sleeve outside the die casting machine. A plunger then forces the metal into the die cavity under high pressure. This method is typically used for alloys with high melting points, such as aluminum, magnesium, and copper.
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