Discussion in 'Metal casting & moulding' started by parneetsinha, May 19, 2014.
Can anybody tell me about aluminium high pressure die casting?
In simple terms you could think of it as the equivelant of plastic moulding for metal. It can produce thin-walled highly detailed parts. Zinc die-casting is often chosen in place of aluminium as it is less aggressive so the dies last longer and more finely detailed parts can be produced.
Aluminum high pressure die casting is a process in which the molten Aluminum is forced into a mold using a die casting machine with a certain pressure. By this method, we can produce products with different thickness and detail.
die casting companies
It is similar to plastic injection molding. But the Alu. alloy should be melt before they are put into the hopper. We do plastic injection molding in Xiamen, China, for clients from US, UK, Russia, Italy, etc.
And to make toy cars!
A brief description of the process:
Molten metal enters the steel form under high pressure. The metal is compressed with the help of a piston machine, as it happens when molding plastics.
The steel form is necessarily heated before pouring the metal.
The main problem to cast in this way is reasonable only for metals with a low melting point.
For steel casting the form is very expensive and is made of heat-resistant alloys and also has a thermal control system. So the parts are very expensive.
Mainly used for casting metals and alloys with a low melting point.
The advantage of this type of casting:
1) Very high performance;
2) Highest casting accuracy compared to any other metal casting technology;
3) Very high surface finish;
4) It is possible to obtain high-quality castings from metals with a low degree of fluidity in the liquid state.
Imperfections die casting:
1) The casting process must be carried out in a vacuum chamber, otherwise parts have a high porosity;
2) Parts cannot have a complex shape, since the form is indestructible and is made of steel;
3) The strength of castings is lower compared to castings obtained by other casting methods. This is due to poor structure, the direction of the grains is uneven and their shape is heterogeneous;
4) Very high cost of casting molds.
This casting method is very well suited for casting small aluminum parts that are not subjected to high loads
Die casting is made:
Automobile engine parts (including aluminum blocks, carburetor parts);
Details of sanitary equipment;
Parts of household appliances (vacuum cleaners, washing machines, telephones);
Parts for the aerospace industry;
Parts for energy industrial;
Parts for centralized heating of apartments and houses;
Also, injection molding is used in the manufacture of computers, smartphones and other electronics.
So the mould is made from steel and the cast parts are made from a different metal? Are there any issues with the parts sticking together? I guess they use some kind of mould release.
What kind of design considerations are there? I would imagine they're similar to injection mould - using a draft angle, maintaining uniform wall thickness, avoiding undercuts etc...?
Under normal process conditions, this does not happen.
In order for such a problem to arise, it is necessary to create ideal conditions: the surface of the form must be degreased and use acid flux for adhesion instead of solid lubricant.
The form may have a refractory coating (paint) and also using a solid lubricant during casting.
The angle of inclination is required for all casting technologies, except for casting into thin shell forms obtained by the method of burning out models.
There is a standard for designing molds for metal casting; all requirements and recommendations are set forth there.
GOST R 53465-2009
I think such standards exist in any country.
Good to know - I didn't know that about the different types of metal.
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