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 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 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

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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October 26, 2013

Details Regarding Aluminum Alloys

Filed under: Aluminum Cast Parts Alloys — Tags: , , , — admin @ 1:56 am

Details Regarding Aluminum Alloys. Metal die cast is an obvious production process involving the die casting of liquid or molten metals into molds complete with hollow cavities shaped as desired, and allowing the alloy to harden for a time. The solidified die cast part is then ejected from the tooling so it can be ready for its intended applications. The alloys used in diecastings are usually those materials that reaches a “cured” state after alloying two or more material components together (similar to: concrete, epoxy, clay and plaster). The alloys die cast process is often used in creating detailed shapes that are often hard to accomplish using other processes.

Zinc Metal (Zinc die casting tooling) parts die casting itself is an age-old manufacturing process, probably dating back to 6,000 years, before branching out into various types using various materials. Zinc diecasting is said to be the most common die casting process of all. Plaster can be cast effectively, as with materials containing the same chemical settings such as plastic resin and concrete. These may be applicable thru single-use waste molds or with multiple-use “piece” molds.

There are even, instances when molds made of ridged pieces and of bendable materials like latex rubber (this must be supported by an outer mold system) can be applied into the process, depending on the uses of course. When diecasting either concrete or plaster, what comes out of it is usually unappealing and lacking in transparency features. This obligated parts manufacturers to paint the surfaces to give the allusion of stone or metal, depending on what it would be intended for.

Also, first layer parts may produce colored sand as an after effect just to give the impression of stone. By using concrete instead of plaster when casting, it would be very much possible to fabricate sculpture patterns, seating for outdoor use and even grand fountains. Simulations utilizing high-quality marble material may be initiated using chemically prepared plastic resins (polyester or epoxy) and adding powdered stone for coloration effects.

A simulation of the materials process will utilize different methods just to calculate the quality of die casting components. These address certain issues and concerns regarding solidification and cooling, mold filling, and many more. The results coming from the methods used provides for quantitative predictions of the mechanical properties of die castings, especially with warping and thermal stresses. The simulation process has the ability to describe every cast component’s up-front quality before production commences. The materials casting rigging procedure can be well designed to work in compatibility with the required properties, setting up for benefits that reaches well beyond pre-production sampling reduction since precise layouts of complete casting systems will also mean significant energy, tolling and material savings.

A software used in the process should work with the manufacturers when it comes to the component designs, including the determining of melting practices and diecasting methodologies through mold and pattern making, finishing and heat treatment. The procedure can save on the casting manufacturing costs. Developed back in the seventies, the die casting procedure simulation became the most important die casting technology innovation coming into the 21st century. It improved the heritage left behind by the seemingly limitless applications of metals die castings.

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

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