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

October 19, 2013

Discovering Aluminum Metal

Discovering Aluminum Metal. The material Aluminum (aluminum) is a metallic chemical element, which is accessible enough and used widely around the world. It is silvery white in color belonging to the boron chemical element group, and not soluble when introduced to water under any normal circumstances. It is ranked third behind oxygen and silicon as the most ample element anywhere, though it is undeniably the most bountiful metal within the Earth’s crust, making up approximately 8% of the Earth surface’s total weight.

Humans make contact with it in many ways, particularly inside the kitchen handling various kitchen utensils and equipment made of aluminum. It is classified under poor metals, having extreme malleability features just like that of lead and tin.

Aluminum alloy itself is very extraordinary because of its low-density characteristic and impressive ability to stand up against corrosion due to the passivization phenomenon. Aluminum material structural components also have vital uses in the aerospace industry and general transportation. Oxides and sulfates are both identified as the most useful aluminum compounds on weight basis at the least.

Aluminums versatility had the aluminum die cast parts industry manufacture roughly $40 billion in various products every year in the US alone, with the automotive industry as being its biggest market. The material is used mainly in different car parts (cylinder heads, radiators, pistons, wheel rims, etc) making the cars themselves significantly lighter. As we are all aware of, lighter cars make for reduced fuel consumption, most especially with the pollution levels emitted. The sectors that benefited the most from using aluminum include the following:

Automobiles and such – Aside from aluminum automotive parts, aluminum airplane parts and motorcycle parts are becoming increasingly reliant on the aluminum element. The recent slow moving sales affected the aluminum industry hard back in 2009. Even so, its uses and applications in cars have dramatically increased as they instinctively turn to the more lightweight aluminum alternative to relieve the transportation sector’s struggles in meeting the fuel-efficiency standards set.

Building and construction – The materials made of aluminum are now fully extended to the roofing, siding, window frames, gutters, hardware and even paint. More than about 1.8 kilograms of different aluminum-made construction materials were reportedly shipped to North America for the year 2009 alone, where a huge portion wound up in materials used for farm complex and highway construction.

Practical uses in Packaging – This is an crucial industry in defining the society today; how we chose to be efficient in our ways. The aluminum material is mostly seen in packaging foils and trays, and even candy wrappers. At a time, the packaging sector even edged out the transportation industry in its use on the aluminum material. The most obvious case for such dependence is the inherent lightweight characteristic, including the fact that it can also be permeable to light or water.

Other uses of aluminum material include important electrical products (light bulbs, phone and power lines). It also made a big impact into the health industry, getting its just place and uses in food additives, antacids, body astringents, and many more. Now you have a good idea how popular the material is in today’s applications.

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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September 28, 2013

Helpful Information to Know About Metal Die Castings

Helpful Information to Know About Metal Die Castings. In today’s marketplace, it is very ordinary to see parts containing materials made from die castings. From lighting fixtures to vehicle parts, die casting has something to offer. Be it simple, tiny parts or big, complex accessories, die casting can mold thousands of stuff made from metal and other applicable materials distributed commercially and industrially.

Do you know about Aluminum Parts Die Casting Production? Die casting is a metal forming process that injects metal into a strong, high-pressured steel mold or die producing accurately engineered metal parts. This process solidifies the molten metal quickly. As soon as the metal hardens, the part is ejected from the die. Die casting is almost the same as permanent mold casting with outcomes characterized by precise dimensions, sharp definition, and high repeatability. It is a versatile process enabling the manufacture of a wide range of durable finishes.

The roots of Aluminum Die Casting Parts Production. In 1838, the first manually-operated die casting machine was invented for the purpose of manufacturing movable type for printers. The first patent of this model was given to Sturges in 1849 for mechanized printing type production. For almost twenty years, this die cast equipment was solely used to make printer types. But by the end of the century, several commercial applications for die cast were discovered, namely: parts for cash registers and phonographs among others. Since then, many other types of equipment for die castings were made to produce various metal tools such as die casting tooling.

Die Casting Equipment. There are two types of machines used for die casting: the hot chamber machine and cold chamber machine. Hot chamber machines, also known as gooseneck machines, normally process metals such as copper, lead, zinc, magnesium, and other low melting point materials that work well with metal pots, plungers, and cylinders. It has a compartment which contains molten metal. This molten metal is then poured towards the furnace through a connecting metal called a gooseneck. Once the molten metal fills the gooseneck, the piston pushes the metal into the die. Cold chamber machines, on the other hand, processes high melting point alloys such as aluminum and others. Here, the molten metal is dispensed to a cylindrical sleeve, or a cold chamber using a manual or automatic hand ladle. The hydraulic plunger shoves the metal into the locked die at a very high pressure.

Alloys Used for Die Casting Production. Die castings make use of non-ferrous or non-iron materials such as zinc, aluminum, magnesium, copper, lead, tin, and bronze. It is also reasonable to die cast iron but it is an infrequent practice.

Zinc alloy: Zinc is very ductile and perhaps the easiest metal to cast and plate. It is highly recommended for small parts and promotes long die life. This is called the zinc die casting process

Copper alloy: Copper is a strong metal with very high wear and corrosion resistance. Among other metals, it exhibits excellent dimensional stability and mechanical properties of alloys.

Aluminum : Aluminum has good mechanical properties and corrosion resistance. It exhibits high thermal and electrical conductivity making it resilient to extremely high temperatures. It is perfect for making thin walls and complex shapes.

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

September 21, 2013

Benefits of Utilizing Aluminum Die Cast Parts in Vehicles

Benefits of Utilizing Aluminum Die Cast Parts in Vehicles. Alloys makes up most of all cars. Without metal, the vehicles, trucks, trains, and all other transportation vehicles we know today won’t be as efficient and as durable as they are now. Aluminum is a popular metal alloy used in most vehicles. From car handles to wheel parts, aluminum can be die casted to fit the necessary requirements of a certain car part. The use of aluminum die casts in making cars is customary. There are several reasons that can be cited to support this claim. Here are the most obvious reasons why aluminum is such an in demand metal alloy in producing vehicle parts and other accessories:

Lightweight. Rare it is for a metal to be described as lightweight, but aluminum exhibits this quality. Since aluminum is a lightweight material, it helps reduce the body weight of the automobile. For a car to get better fuel economy, it has to be light. And as aluminum helps make cars fuel efficient, it continues to deliver excellent performance. http://www.cast-parts.com

Real Value. Aluminum car parts are easy and cheap to produce. Major car makers love using aluminum in their products because these die casts are produced in thousands every year at a very low cost. Aluminum is among the easiest to mold and requires lesser processing time compared to other non-ferrous metals. In fact, some auto manufacturers choose to have their own die cast equipment so they can just produce their own parts and further their savings. On the other hand, some automobile manufacturers, especially those who operate in a smaller-scale, may just opt to buy pre-fabricated aluminum die cast car parts from mainstream manufacturing companies.

Versatile. Aluminum is a flexible metal with good mechanical properties and dimensional stability. Thick or thin specifications, complex or simple shapes, big or small parts, smooth or textured, aluminum can take in any of these alterations to produce the right parts. It can be used for billets, rods, sheets, coils, handles, etc. In heavy equipment such as tractors and trucks, aluminum parts being produced today include multiple axial fittings, engine blocks, sprockets, and gears. Also, they can be textured rough or polished to a smooth shine.

Strong. Though known to be lightweight and pliant, aluminum is a strong metal. Casting aluminum, compared to raw aluminum, has a more compact molecular built making it more resilient to breaking and fair toughness making it withstand fatigue due to repeated loading. Consumers and vehicle makers admire its toughness to deformation. In addition to that, aluminum has a high melting point and high resistance to corrosion so it’s guaranteed to last a long time.

Easy to Process. Die casting parts reduces production cost in leaps and bounds because metals that undergo this process are often ready to use and do not need trimming or post-machining. Die casting employs molds that can shape even the narrowest wedges or smallest details to achieve high precision.

As you can see, aluminum is lightweight, economical to use, flexible, tough, and easy to process. These five characteristics make aluminum die casts perfect for making parts for vehicles that is why many car companies have shifted from using traditional metal products to die cast produce.

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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August 31, 2013

Three Common Causes of Die Casting Porosity

Filed under: Aluminum Casting Parts,Cast Parts — Tags: , — admin @ 1:19 am

Three Common Causes of Die Casting Porosity. Die casting porosity is an inevitable kind of defect that metal casting companies encounter. With mass production of metal casting parts, such defect is proven to be difficult to avoid even for big manufacturers.

What is die casting porosity? Die casting porosity is the formation of tiny pockets of void spaces within a metal casting part. These spaces contain gas which was normally formed after the metal casting part has cooled down.

If you wonder what causes this kind of defect, this article will give you three common causes of die casting porosity.

1. Aggressive Mixing.

During the process of mixing hardeners and casting resins, you must avoid inducing air into the mixture. You can use mixers from Jiffy Mixer line because it is said that their machines induce less air than other mixers. The most effective way to remove air due to the mixing process is to degas or de-air the mixture inside a vacuum chamber before you proceed to pouring.

2. Injection temperature

In die casting, injection is the process when the molten metal is pushed, using high pressure, into the die or mold. If the injection temperature is too high, chances are, the die casting part will form air bubble because the casting resin will boil.

3. Cooling rate

Air bubbles within the die casting parts are sometimes caused by non-uniform cooling rate. The cooling rate depends from the maximum wall thickness of the mold, the thermodynamic properties of the metal used and also the complexity of the mold itself.

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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August 24, 2013

Die Casting Porosity and Its Causes

Die Casting Porosity and Its Causes. Die Casting porosity is one of the most common defects in the die casting manufacturing industry. What is die casting porosity? Die Casting porosity is a type of die casting factory defect in which the die cast parts have tiny spaces which contains air within the metal – hence, the die cast parts become porous. The porosity of die casting parts could weaken the parts itself if the spaces or voids are very large.

To clearly understand the causes of the porosity one must know the basic of the die casting process. In a nutshell, die casting process involves molding molten metal by placing it inside a short cylinder, and then a great force is applied by a piston connected on the cylinder, pushing the molten metal so it would take the shape of the die cast die or die cast mold. During this process, the metal is forced along with the air inside of the cylinder to the die casting mold.

Die casting porosity could be contributed by many factors like the following:

• Die casting machine pressures.

• Temperature of the metal and the mold.

• The cleanliness of the materials used.

• Design of the die casting mold.

• Design of the die casting part.

• The shot speed of the die casting machine used.

• Die casting mold release or die casting spray

Die casting manufacturers use metals that are non-ferrous or metals that don’t contain iron. It is because iron content is the main reason for oxidation and rusting. Non-ferrous metals include magnesium, tin, lead, copper, zinc and aluminum.

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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