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Views: 56 Author: Site Editor Publish Time: 2023-11-28 Origin: Site
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
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.
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.
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:
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% | ||
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 | ||
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
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:
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.
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.
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.
This method creates sturdy and dimensionally stable parts while maintaining tight tolerances and resistance to heat.
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.
The cold chamber die casting process involves the following steps:
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.
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.
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.
The casting is then removed from the die and any excess material is trimmed off.
There are both automatic and manual variations of the 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.
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.
The die (mold) is prepared with the desired cavity shape for the component to be cast.
The die halves are closed and clamped together under high pressure.
The automatic machine injects the molten metal into the die cavity at high pressure, ensuring the material fills all intricate details of the mold.
After injection, the molten metal is allowed to cool and solidify in the die.
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.
The process is repeated for the production of multiple components in a highly efficient and automated manner.
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.
In manual cold chamber die casting, operators manually melt the metal, typically in a separate furnace.
The molten metal is manually transferred to the cold chamber of the die casting machine by ladle.
The die is prepared manually for the specific part to be cast.
Operators manually close and clamp the die halves together.
The molten metal is manually injected into the die under pressure.
The cooling process is allowed to occur naturally or may be assisted by cooling systems.
Once the metal solidifies, operators manually eject the casting from the die.
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.
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.
2. Molten metal (magnesium, zinc/zamak alloy) be injected into die casting mold cavity by die casting machine plunger.
3. Die casting die open. After injection, insert core or slider move out, and movable die open.
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.
5. Mold closing, ejection pins, insert core or slider back to position. Ready for next die casting cycle.
KYLT Aluminum, Zamak alloy diecast services, please email us: cnkylt@aliyun.com
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 |
Zamak part for Forklift reflector
Zinc Bus door handles
Zinc connector for chair
Aluminum die casting parts - motor cover
Powder coated aluminum die casting parts
Cold chamber aluminum die casting
Aluminum die cast part by CNC turning
CNC lathe machined aluminum die cast parts
Aluminum electric box for Electric vehicle 
Aluminum die casting motor housing
Aluminum die cast natural gas meter box
Aluminum chair parts with shot blasting
Aluminum motor housing with powder coating
Aluminum cast chain shell with powder coating
Aluminum radiator with painting
Aluminum alloy cleaning machine pump body with CNC machining
Electric cutting machine Aluminum protective cover
Aluminum Electrical box 
LED light Aluminum cooling base
Finished aluminum zinc die casting parts assembly service
Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.
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
Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.
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.
Email us: cnkylt@aliyun.com Get a Free instant quote for your Aluminum & Zinc metal products.
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.
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.
