Die Casting Blog for Cast-Parts Aluminum Die Cast Parts and Zinc Die Cast Parts manufacturing and cast parts production

November 30, 2013

Aluminum Alloy Die Cast Parts Essentials

Filed under: Aluminum Cast Parts Alloys — Tags: , — admin @ 1:22 am

Aluminum Alloy Die Cast Parts Essentials. When it comes to versatility and durability, zinc as a material for the diecasting process is one of the top choices in the list. Most manufacturers opt for zinc alloy diecasting for the production of parts and items such as those used for golf clubs, lock housings, motorcycles and automotive, and home fixtures among others. The technologically advanced equipment that are used today for the zinc alloy die casting method make it more convenient to produce near perfect replicas of any metal products. The precision in size, shape, and texture allows for efficient and economical mass manufacture of items and parts for the manufacturing sector. aluminum as a material for die cast parts also allows for the output to be finished as the customer may prefer. Among the finishing processes that could be done on a aluminum die cast part include polishing, chrome or nickel plating, and powder or brass coating – the most common finishing is nickel plating which leaves the surface of the aluminum alloy die cast part a smooth and shiny.

The method of zinc alloy die casting is similar to other material die casting methods in that it uses a molten material that is pressure injected into molded cavities. Die casting using zinc material could either make use of the hot chamber method or the cold chamber method. In the hot chamber method, the zinc is melted and fed into the die cavity using a pneumatic piston or a hydraulic piston. While this method works well with zinc alloy, this kind of process is not recommended for some materials like aluminum and those with aluminum components since these metals can sweep with it some iron components of the molten pool. Lead-based alloys like tin and lead are best used for the hot chamber method. The cold chamber method, on the other hand, is also a good process to use for aluminum castings. With this method, the casting metal is melted in a separate heating chamber after which it is fed into an unheated injection cylinder that in turn feeds it into the die. As the molted alloy passes through several stages, the cold chamber method takes longer to complete, resulting in slower cycle times.

Aluminum alloy is one of the most preferred metals in diecasting. Aside from its flexibility in use for both the hot chamber method and the cold chamber method, the properties of aluminum lend itself best for use in the die casting process. In its melted form, the aluminum alloy presents outstanding fluidity while its solid state offers high strength and hardness. Another advantage to aluminum die casted products is its excellent corrosion resistance and its capacity for high heat and electrical conductivity. More information about what metal parts are made best with aluminum die casting are available in various online sites. Aluminum die cast is a widely acceptable producing process that turns out some of the most durable metal parts used in various commercial needs.

Cast Parts Company produces cast parts using the Aluminum Die Casting Process. Look at this website page for more details: www.cast-parts.com/diecasting.html

November 23, 2013

Die Casting Beginning – Creation Method Also Specific Details

Filed under: Cast Parts — admin @ 1:44 am

Die Casting Beginning – Creation Method Also Specific Details. Die Casting is a process in the metalworking industry that is used to produce engineered zinc or aluminum parts like aluminum die cast heat sinks. The methods along with its diverse methods are very versatile. The products range from simple pieces to intricate and highly defined parts utilized in various machines. Modern technology has made it possible for producers to come up with both serviceable and attractive output.

An output derived from the whole process come in huge volumes and is utilized in various industrial products. Die casters manufacture both commercial and consumer components and parts that are in turn utilized in other industries. A lot of the cast items can readily be seen at home, which includes toys, faucets, car parts, and other items that are used daily. All these products are made from die cast molds and tooling

Die casting History

This history of our metalworking process traces its origin to the mid-1800s. The first patented technology that uses this very method dates back to 1849, which is for a machine that fabricates types for employed in printing. The machine was manually operated unlike the ones utilized today. Even though it may seem that this initial use was a bit crude, it paved the way for more intricate and elaborate processes that manufactured more complex components. However, the production of printer’s type was the initial product and would be until 20 years later.

People began to try working new items using the new found technology as the years went by. Items in various shapes and forms were experimented on – some worked and others failed, which is how things really in the field of invention. The more successful produce included component parts for phonographs, which were starting to become popular during that era. Parts for cash registers were also mass manufactured during this time.

The mass production age of Die casting had a kick off in the 1900s. At the turn of the new century, a lot of developments ensued. This includes the introduction of new metals that will later become leading metals to be employed in the metalworking industry where metal casting is utilized. Zinc alloys and aluminum metals were introduced into the method in 1914, which is nothing but a revolutionary idea in the works.

The zinc alloys like copper and magnesium also came into play. These new metal metals provided a wide spectrum of advantages and uses. Zinc made it easier for manufacturers to cast more intricate parts due to its low melting point and high ductility. Aluminum metals allowed them to fabricate corrosion resistant components. These are only a few die casting alloys

The light weight of magnesium alloys allowed manufacturers to fabricate lighter parts. The wider variety of metals provided more options to manufacturers. It also opened the way to furthering the current technology currently in use.

The Die Casting technology also improved with the times. The variety of aluminum alloys to work on allowed producers to experiment on other methods not previously used. The original procedure utilized by producers and metalworkers was low pressure injection. This process worked for a while but it was in nowise perfect.

Other methods were later developed like gravity pressure and high pressure Die Casting . Newer methods include squeeze and semi-solid casting. Advancement both in the Die casting technology employed and the metals employed by www.cast-parts.com should be expected.

Cast-Parts Die Castings Blog gives information on how to get a Aluminum and Zinc Die Castings. If you are looking for Die Casting Parts look at this website.

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Cast Parts Die Casting Company
6918 Beck Avenue
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November 16, 2013

Benefits of Aluminum Metals and the Zinc Diecasting Method

Filed under: Aluminum Cast Parts Alloys — Tags: , , , , — admin @ 1:33 am

Benefits of Aluminum Metals and the Zinc Diecasting Method. Aluminum die casting process have been used in metalworking as early as 1914. The aluminum metal has since been one of the metals usually favored by many manufacturers due to its inherent properties. The other metal alloys that are in use today include lead, tin, copper and magnesium. Each of these metals are employed due to their intrinsic diecasting characteristics.

Among all these alloys, zinc is the metal alloy that is easiest to cast compared to the other metals utilized in the casting industry today. Other qualities such as great impact strength and ductility make it very useful. This metal alloy can also be plated rather easily and producing small diecasting parts simply a breeze. Because of its low melting point, the die’s service life is lengthened since it isn’t subject to a lot of intense heat.

History of Zinc Diecasting

Casting as a process used in the metalworking industry has been around for centuries. The technology of pressure injection die casting and gravity pressure casting has been around since the middle of the eighteenth century. The first patent to be issued for such a technology was awarded to Sturges in the year 1849. This was in line with the invention of the diecasting machine used to manufacture printing types.

For the next two decades, castings were produced only for the movable type used in printing. Other developments with this technology ensued some time after. Other shapes were experimented on and in 1892 a lot of commercial applications were then included and eventually manufactured. This casting technology made it possible for industry leaders to mass produce various die casting parts for cash registers and phonographs among many other things.

Importantly also the casting metal alloys that were employed in metalworking back in the early days incorporated lead and tin in a variety of compositions. In 1914 aluminum and zinc alloys were introduced and were favored because of the advantageous characteristics of these two metals. The other popular metal alloys used to this day followed several years later, which includes copper and magnesium.

Similarly, the casting process along with other specific procedures like Aluminum casting underwent an evolution. The diecasting metalworking industry initially used low pressure injection. Other casting methods and processes were introduced later including high pressure diecasting, semi solid casting, and squeeze die casting. As the technology improved the ensuing output obtained better surface finishes, high integrity, and near net shape properties.

Zinc die casting process and other diecasting processes will continue to evolve. A lot of refinements in the currently used production processes will still be made. A huge amount of research is also put into the development of the die casting alloys being used in the industry. The goal in this research and development drive is to expand the number of diecasting applications for the manufactured products and eventually enter other possible markets.

Imagine, the initial applications were just for very simple lead types, which are fairly easy to produce. Nowadays, die casters are able to mass produce a lot of intricate casting parts for automobiles, toys, and other intricate materials. The advancement in zinc www.cast-parts.com technology has made it possible to create dimensionally precise diecasting parts and a lot is expected in the near future.

Cast Parts Company produces cast parts and Aluminum Die Casting Tooling and Zinc Die Casting Tools. Look at this website page for more details: www.cast-parts.com/diecasting_tooling.html

November 9, 2013

Zinc Die Casting Manufacturing Technique and Related Attributes

Filed under: Aluminum Cast Parts Alloys,Aluminum Casting Parts,Die Casting Company,Zinc Casting Parts — Tags: , , , — admin @ 1:22 am

Zinc Die Casting Manufacturing Technique and Related Attributes. Aluminum die cast manufacturing is one of the many known metal casting processes being utilized in the metalworking industry today. Other than zinc, other alloys use other materials as well, which includes the following – lead and magnesium. Each of these casting metals has its own unique attributes that make them pretty useful.

For instance, among these said metals, magnesium is the one that is easiest to machine and it has a pretty good ratio between its weight and strength. On the other hand zinc is very easy to cast. It also has high impact strength and is really cost saving when manufacturing small parts.

Zinc Die Casting Metal Working Technique and Related Attributes

The technique of metal die casting involves injecting liquefied molten metal into steel molds that are otherwise known as die cast tooling. Certain characteristics of aluminum alloy make it well suited for certain uses. First off, this metal alloy is corrosion resistant unlike iron that is prone to rust and quick decay. The materials that are created using aluminum metal tend to be lightweight and easier to transport.

There are other characteristics of aluminum alloys that make them very useful. Its high dimensional stability works very well for manufacturing thin walls and very complex figures. It also has great mechanical properties and it can remain very sturdy in spite of high temperatures. This metal alloy is also a good conductor of electricity and heat.

Accepted as the traditional method of aluminum die casting manufacturing is also called high pressure diecast manufacturing. This method of diecast manufacturing has four consecutive steps – die preparation, filling, ejection, and finally shakeout. The preparation stage incorporates spraying lubricant into the cavity of the die, which helps make it easier to remove the aluminum metal. Lubrication also helps in temperature control.

After the die is lubricated and prepared, molten aluminum alloy is injected into the enclosure using very high pressure, which is where the name of this method was taken. The pressure in the die usually ranges from 1,500 psi to 25,400 psi, which is maintained until the metal alloy solidifies.

Once the alloy inside have solidified then the dies are opened and the shot is ejected. The final step in the traditional method of aluminum die cast manufacturing is called the shakeout, simply because the scraps are removed or shaken off the casting. Manufacturers utilize a trimming die that is mounted on a power or a hydraulic press in the final step in the entire process.

Better or Worse – Therefore a huge amount of pressure is used to fill the die, the cavity that needs to be filled by the cast is easily filled before any part or portion of the molten metal solidifies. This basically solves the initial problem of discontinuity in the casting. The drawback to this method is that air gets entrapped pretty easily thus producing small pockets or pores.

Regarding the amount of porosity in the center of the cast alloy part, vents are incorporated into the die. These vents are usually placed along the parting lines. Other finishing processes such as plating, hole-tapping, and buffing are utilized in order to obtain the best output in Aluminum die casting manufacturing.

Cast-Parts Die Castings Blog gives information on how to get a Aluminum and Zinc Die Castings. If you are looking for Die Casting Parts look at this website.

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November 2, 2013

Uses and Values for Metal Die Casting Parts

Filed under: Cast Parts — Tags: , — admin @ 1:10 am

Uses and Values for Metal Die Casting Parts. Diecasting Aluminum alloy parts for one are feasibly valuable, impressively lightweight, and they can look great on just about anything. Another benefit of parts cast out of aluminum is the fact that even though surface finishes add to the value of finished parts, a finish is generally not as important as to the vital functions and uses of the casting parts in the applications since steel will corrode noticeably whatever happens. The main reason why aluminum casting parts are cheaper compared to their counterparts in the industry is that aluminum die castings can be readily machined at much faster than most materials used.

Special parts made from aluminum die castings are vital components in different products and seemingly endless applications. Examples of such diecasting parts would include containers and lids for electronic device enclosures, automotive die cast parts, door handles, truck parts, engine and cooking utensils, lighting parts, optical reflectors, and especially with aerospace and military.

Making aluminum die casting parts through casting any molten aluminum into casting molds may seem easy enough, though it can quickly become technically challenging. The casting process is relied upon by several industries in creating wide ranges of useful parts. Given the right tools and safety precaution, any amateur hobbyist is well able to create aluminum die castings from molds with numerous shapes and cavity depth.

In your case, you can start by constructing a replica of the parts that will be used in diecasting using polystyrene foam material and a knife. You can create composite shapes by cutting through individual shapes and joining them together using hot glue. Place a sprue shape on top of the part. With a layer of sheet rock mud coated around the polystyrene, you now have the ability to diecast for a smooth surface finish.

Remember in sand casting to introduce sand inside the casting flask. Secure the polystyrene part within the flask with packed casting sand around the aluminum part. You can accomplish this by using a tamping rod so you can compact sand all around the part. Make available a metal rod that creates vent channels into the polystyrene. Continue with the packing of the sand all around the part and all the way to the sprue. You can now remove he rod from the sand and at the same time place the casting pressure tool over the sprue to make way for the pooling of the aluminum.

Load the scrap diecasting aluminum into the crucible. Heat it to start the melting of the aluminum. Once fully melt, you can now die cast molten aluminum all the way into the sprue. You can expect it to melt the foam away, filling the void within the sand. The vent is there to allow any unnecessary gas to escape.

Allow time for the cool down of the die cast aluminum material. A couple of minutes should do. Remove the sand first before you take the aluminum die casting. Take note that the aluminum casting is still dangerously hot at this stage.

Alloy casting manufacturing aluminum parts is highly regarded as a dangerous activity that fully requires the proper equipment and procedure. Always consult any experts first at www.castings-aluminum.com before you get to diecast aluminum metal on your own.

Cast Parts Company produces cast parts and Die Casting Parts. Look at this website page for more details: www.cast-parts.com/diecasting_parts.html

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