Injected casting is a manufacturing process in which molten metal is poured or pressed into steel molds. Molds, also called equipment or die, are shaped using steel and are mainly designed for every project. This permits each constituent to be created with accuracy and repeatability. Aluminium, zinc and magnesium are the most widely used die-cast alloys.
Benefits
Die casting can have significant advantages in other manufacturing processes, often leading to considerable cost savings, not only in terms of price per se but also in the total cost of production. When a part is a cast, complex final shapes can be created, including external threads and complex internal geometries with minimal stripping angles. Multiple fractions can also be shared into one. This helps in getting rid of assembly operation and dropping labour costs.
Other benefits include:
Variable wall thickness
Tighter tolerances
Fewer stages of production from raw material to finished part
Fast production cycle times
Reduction of waste material
The long-lasting tool, especially for zinc and magnesium
Injected cast alloys
Zinc, aluminium and magnesium are the three main injected cast alloys. Cast alloys not only withstand high operating temperatures but are also fully recyclable. Cast alloys also have:
- Good corrosion resistance
- High strength and hardness
- High thermal conductivity
- High electrical conductivity
- Exceptional EMI or RFI protection properties
- Good finishing characteristics
Separately, each cast alloy offers a variety of benefits that the others may not. There are no limits when choosing the right metal.
Process
There is no single process that can be adapted to each project. Every project is different; that’s why Die Casting Manufacturer offers multiple solutions for your die casting needs. This ensures that the right process is always used for the right application.
Hot chamber
Used in zinc, some magnesium alloys, and other low melting point alloys. High-temperature chamber die casting is ideal for alloys that do not easily erode or attack metal crucibles, cylinders, and plungers.
Cold chamber
It is best suited for metals with high melting points, such as aluminium, during cold chamber injection molding. The metal liquefies and then casts in a cold chamber where a hydraulically actuated plunger pushes the metal into the mold.
Mounted by injected metal
The Aluminum Die Casting Companies have developed and refined our innovative die-cast metal assembly, a one-step manufacturing method. They perform most adhesives used to bond small components and assembly production.
Conventional multi-slide die casting
There are two different types of tools: multi-slide and conventional. Each has its advantages, and the qualified experts can help decide which tool is best for each project.
Benefits of multi-slide tools
The patented multi-tool tool technology offers several unique benefits, including:
The piece finished from the beginning
Elimination of secondary operations, such as assembly and mechanization
Minimal piece-to-piece variation compared to conventional multi-cavity molds.
Benefits of conventional tools
Conventional Aluminium Die Casting molds are designed with single or multiple cavities. The mold is designed to be efficient and reduce secondary operations helping to reduce costs. Other benefits of conventional casting molds include:
- Molds that are designed to effectively manage a high production volume
- Finished cast part, with a focused design to avoid secondary operations
- Reinforced steel dies for tool life
- Efficient production with properly planned cooling and water circuits
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