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

March 15, 2014

Advantages of Aluminum Materials and the Zinc Part Casting Process

Filed under: Aluminum Cast Parts Alloys — Tags: , , — admin @ 1:26 am

Advantages of Aluminum Materials and the Zinc Part Casting Process. Aluminum part casting process have been used in metalworking as early as 1914. The aluminum material has since been one of the metals usually preferred by many manufacturers due to its innate properties. The other metal alloys that are in use today include lead, tin, copper and magnesium. Each of these metals are used due to their intrinsic casting characteristics.

Among all these alloys, zinc die casting process is the metal alloy that is easiest to cast compared to the other alloys used in the die casting industry today. Other characteristics 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 Aluminum Die Casting

Casting as a process used in the metalworking industry has been around for centuries. The technology of pressure injection diecasting 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 die casting machine used to manufacture printing types.

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

It should be noted that 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.

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

Zinc casting and other die casting 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 casting applications for the manufactured products and eventually enter other possible markets.

Look ahead, 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 aluminum www.cast-parts.com technology has made it possible to create dimensionally precise casting parts and a lot is expected in the near future.

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 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 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

Technical Issues Regarding Die Cast Parts and Its Uses

Filed under: Aluminum Cast Parts Alloys,Aluminum Casting Parts,Cast Parts — Tags: , — admin @ 1:07 am

Technical Issues Regarding Die Cast Parts and Its Uses. Die Castings are just similar in nature with permanent mold casting, with the exception of the metal under high pressure (10-210 MPA) injected directly into the tool. The result would be a more uniform part, clean surface finishes complete with excellent dimensional accuracy, as better as 0.2% in precise die casting dimensions. For the other die casting parts, manufacturers wouldn’t have to worry about post-machining anymore, since the whole procedure can now do without it.

The die casting production process is accomplished using either the cold or hot chamber die casting process. The cold chamber die casting process is characterized by directly ladling melted metal into the mold for each shot. Here, there is considerably less exposure time of the melt making contact with the plunger walls, which comes in handy for important metals (aluminum, copper and all of their die casting alloys) that would alloy with iron easily in high temperatures.

A hot chamber casting procedure on the other hand requires the pressure chamber to be connected directly to the tool cavity. This should make for a permanent immersion of the molten material used in the process. The pressurizing cylinder’s inlet port would be uncovered for the plunger to move into open space freely. This development allows new molten die casting metal charge to fill up the die cavity much faster than that of the cold chamber die casting process. This method is mainly used for those die casting metals with low melting points and higher fluidity characteristics (zinc, tin, and lead).

Casting molds are costly since they are made entirely from hardened steel, with the exemption of harder and stronger metals that cannot be die cast (steel, iron). Another factor would be the relatively long cycle periods needed in building these casting mold types.

Common metals utilized in the die casting process include aluminum, copper alloys and zinc. Pure aluminum on the other hand is used rarely because of its high shrinkage characteristic and vulnerability to hot cracking. It is alloyed instead with silicone, making for increased melt fluidity, significantly reducing its machine ability. Copper is another important element that increases hardness when alloyed. It has the ability to reduce ductility and corrosion resistance. Copper alloys are important components in marine and electrical applications where wear and rusting plays a fundamental role in the process.

Die casting processes using magnesium are limited at 20 kg max, and up to 35 kg max for zinc. Large casting operations normally suffer from greater porosity problems, most probably due to entrapped air that initiates the solidifying of the melt even before it gets a chance to extend to the edges of the die casting die cavity. Manufacturers get side step this through vacuum die casting.

From a design efficiency angle, it would be smart to conceptualize die casting parts with uniformed breadth on the walls and its cores of uncomplicated designs. The heavy sections of die castings bring up some severe cooling problems, with trapped gasses wreaking havoc with the die casting part and causing porosity. Manufacturers at www.castings-aluminum.com must see to it that all corners be radii with extra space just to avoid stress concentration.

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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818-982-9386 Phone
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