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

May 22, 2009

Die Casting Mold Processes

Filed under: Die Casting Tooling — Tags: , , — admin @ 6:47 pm

Die Casting Mold Processes. Die casting has a similarity to permanent mold casting. The exception is metal is injected into the mold or die casting mold under the high pressure which results to a good surface finish and accurate dimension. Die casting can use cold chamber or hot chamber process.

In a cold chamber process, molten metal is gradually transferred into the cold chamber for every shot. This is useful especially for metals like Aluminum, Copper and its alloys. There is less time exposure of melt to the plunger.

In a hot chamber process, the pressure chamber is connected to the die casting tooling cavity. It is permanently immersed in the molten metal. Pressurizing cylinder inlet port is uncovered as plunger moves to open portion, which allows molten metal into the cavity. This hot chamber is useful for metals of low melting point and high fluidity. Examples are Zinc, Tin and lead that does not alloy easily with the steel.

Die casting molds and tools have a tendency to be expensive because they are produced from hardened steel and has a long cycle time to build. Also, iron and steel are very strong and hard metals and therefore cannot be die cast.

Zinc has high melt fluidity and can therefore be made to close tolerances and with thinner walls than Aluminum. It is alloyed with Aluminum and this makes it hard and strong. Casting is at fairly low temperature (425ºC). Zinc alloys are used to manufacture precision parts like connector housings, sprockets, gears, etc. Copper alloys are useful in electrical, marine and plumbing. They are corrosion and wear resistant.

Cast Parts Die Casting Company
6918 Beck Avenue
North Hollywood, CA. 91605
818-982-9386 Phone * Sales@Cast-Parts.com.

May 20, 2009

Aluminum Die Casting and other Methods

Filed under: Aluminum Casting Parts,Cast Parts,Die Casting Company — admin @ 1:52 am

Aluminum Die Casting and other Methods. Aluminum die casting process is seemingly the more advantageous method nowadays when it comes to metal casting as compared to others like forging, screw machine production or stamping. This is due to the fact that die casting, particularly aluminum parts die casting, allows for innovative and modern techniques and ways that enable the delivery of all types of shapes, even extremely complex ones. This is very much unlike stamping. Aluminum die cast parts also offers many variation in terms of the measurement of each section’s thickness thereby ensuring the production of die cast parts that are precisely measured. One die cast may replace a number of stamping already, which only means that die casting process allows for a shorter assembly time. This means greater savings for both the manufacturer and the customer.

When compared to forging, aluminum die casting process gives a wider choice of shapes that has thinner walls as well as closer tolerance. The parts from die casting lower costs when it comes to finishing and it accommodates coring holes use. This is not possible with forging.

Lastly, when compared to screw machine production, aluminum die casting process makes possible hard to produce shapes with the use of bar or tubular stock. It is again more cost saving because it manages to observe tolerances without necessitating the use of tooling adjustments that are quite expensive. These facts only mean that die casting process compared to screw machine production does not only save cost but also cuts down waste and demand lesser operation.

Due to the above reasons, aluminum die casting manufacturing is becoming the choice of die casters.

Cast Parts Die Casting Company
6918 Beck Avenue
North Hollywood, CA. 91605
818-982-9386 Phone * Sales@Cast-Parts.com.

May 17, 2009

Hot Chamber And Cold Chamber Die Casting

Filed under: Cast Parts — Tags: — admin @ 4:29 pm

Hot Chamber And Cold Chamber Die Casting. In the process of die casting, molten metal in injected forcibly into mold cavities, or “dies”, under very high pressure. Because this method of molding metal is extremely versatile, die casting is widely used as a method for forming metals into specific shapes. While it may use a similar process as mold casting, die casting uses pressures of up to 10 to 210mpa to inject metal into the die. The resulting material exhibits uniformity of parts, dimensional accuracy, and smooth surface finishes.

There are many different materials used in die casting, such as copper, zinc, tin, magnesium, and lead. However, aluminum die casting is the most widely used compared to these other materials as the metal is more malleable, and is good for creating large size cold chamber die castings, to die castings composed of tiny and complex parts.

There are two processes used for die casting, namely the cold chamber which produces cold chamber die castings, and the hot chamber process. To produce cold chamber die castings, a cold cylinder is injected with molten metal. With less time exposure given for the metal to be propelled into the mold, cold chamber processing is more often used for metals that easily meld with iron at very high heat. The cold chamber process is also used for metals that have high melting points.

On the other hand, in the hot chamber zinc die casting process, the pressure found in the die cavity connected to it becomes permanently a part of the molten material. A plunger is propelled toward an area that is non-pressurized, uncovering the inlet port appended to the pressure cylinder.

Cast Parts Die Casting Company
6918 Beck Avenue
North Hollywood, CA. 91605
818-982-9386 Phone * Sales@Cast-Parts.com.

May 16, 2009

Aluminum Cast Parts Preferred

Filed under: Cast Parts — Tags: — admin @ 4:46 pm

Aluminum Cast Parts Preferred. Aluminum cast parts are now the preferred end products from metal casting particularly die casting. Die casting is a manufacturing process by which molten metal is forced into mold cavities done under extremely high pressure. These mold cavities are actually machine into dies. Most of these die castings are made from metals like copper, zinc, lead, tin and aluminum, which is showing some momentum and are being preferred by many die casters.

One simple reason for this is the fact that aluminum still is one of earth’s most abundant metal. It is lightweight, malleable and flexible but strong and corrosion resistant. Not only that, it is recyclable, making it environment friendly. Currently, aluminum cast parts process is used to produce a lot of aluminum part castings found in automobiles and many auto parts. In North America alone, one of the largest market for aluminum cast parts are from its transportation industry. It is in fact the 2nd most used component in car and truck production. This is because aluminum may reduce gas consumption due to aluminum made vehicles being lighter in weight. Vehicles made of steel are 1/3 heavier than if it is made of aluminum. With the use of processes like forging, rolling and casting, aluminum may be processed to become longer and even thinner. The most used forms of aluminum in the market are foils, sheets and plates.

Given these advantages in using aluminum than other metals, it is expected to be the metal of choice in many more products. Truly, aluminum is expected to gain more popularity in the coming days.

Cast Parts Die Casting Company
6918 Beck Avenue
North Hollywood, CA. 91605
818-982-9386 Phone * Sales@Cast-Parts.com.

May 12, 2009

The Process of Hot Chamber Zinc Castings

Filed under: Zinc Cast Parts Alloys,Zinc Casting Parts — Tags: — admin @ 8:16 pm

In the hot chamber zinc die casting process, slabs of zinc are liquefied inside a furnace with a temperature of approximately 700-800 degrees Fahrenheit. When melted, the zinc metal stays in the furnace. The gooseneck or shot sleeve is immersed in the hot chamber and the molten zinc is injected into the two die halves being held together by the machine. The two halves of the die casting molds are mounted on the die casting machine and the machine shuts off and clamps the two die halves together. The molten zinc metal is under high pressure until such time that the metal solidifies (approximately less than a minute). Die halves then open up and the part or parts are ejected and taken out either manually or automatically. Finishing works include trimming, tumble deburring, precision machining, painting, anodizing, chrome plating and assembly.

Hot chamber zinc die casting machines are used mainly for zinc, lead, magnesium, copper and other low melting point alloys that do not easily erode metal furnace pots, plungers and cylinders. The injection mechanism of a hot chamber zinc casting machine is soaked in the molten metal bath of a metal holding furnace. The furnace is connected to the machine by a metal feed system called gooseneck or shot sleeve. As the injection cylinder plunger goes up, a port in the cylinder opens, permitting hot molten metal to enter into the cylinder. As the plunger moves downward, it shuts the port and forces molten hot metal into the gooseneck and nozzle into the die cavity. When the metal has already solidified in the die cavity, the plunger is removed, the die opens and the casting is ejected.

Cast Parts Die Casting Company
6918 Beck Avenue
North Hollywood, CA. 91605
818-982-9386 Phone * Sales@Cast-Parts.com.

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