Die Casting

An efficient, economical process offering a broader range of shapes and components than any other manufacturing technique

Most widely used metal forming processes,incredible versatility,reliability,repeatability, reasonable cost

Die Casting Service

Die casting is a highly productive method of casting parts with low dimensions tolerance and high surface quality.

 

Die cast parts are important components of finished products ranging from automobiles to light fittings which including

automotive connecting rods, pistons, cylinder beds, electronic enclosures, toys, plumbing fittings.

 

The molten metal injection is carried out by a machine called die casting machine.

 

Die Casting can be carried out via High Pressure or Gravity die casting methods. and there are two different ways of manufacturing components: hot chamber and cold chamber die casting. In both manufacturing processes, the mold is sprayed with a release agent prior to the casting process in order to ensure that the subsequently cast part can be easily remover from the mold.

 

Hot Chamber Die Casting Method

A characteristic feature of hot chamber die casting machines is that the casting chamber is constantly in contact with the liquid alloy. The melt passes through a valve into the casting chamber, where it is pressed at high speed into the closed die casting mold by the piston. This process is used for alloys with a low melting point, such as zinc, lead or tin.

 

Cold Chamber Die Casting Method

Cold chamber die casting machines are designed in such a way that the casting set is located outside the melt which is the most popular process in the mass production of light metal castings. To produce a component, the alloy is filled into the casting chamber and pressed into the die casting mold through channels. This process is suitable for materials with a higher melting point. These include, for example, aluminum and copper.

 

After the alloy has been pressed into the mold in both processes, the component solidifies under the strong pressure, whereupon the latches of the mold can be opened. The part with gate is removed from the mold by automatically operated ejection pins and can be further processed if necessary.

 

Materials for Die Casting

Zinc, aluminum, and magnesium are the three main die casting alloys. Among that, aluminum is one of the most important materials with a share of more than 80 %, followed by zinc and magnesium. However, copper, lead and tin can also be used. The alloys have different properties. For example, aluminum (600°C) and magnesium (520°C) have a high melting point, zinc (380°C) and lead (320°C) a low melting point.

 

Certainly, in die casting, non-ferrous metals are used to manufacture components, and the choice of alloy for a particular application depends on budget, weight and material properties.

 

ADVANTAGES BY DIE CASTING

  • It is a manufacturing process that produces accurately, defined, smooth and textured-surfaced metal parts
  • Dimensional accuracy and stability, with die casting, you get the parts dimensionally stable while maintainning close tolerances
  • Thin walls, die casting allows for the production of casts with thinner walls when compared to other methods
  • Allows a high volume of die casting parts to be produced very quickly - thousands of identical castings can be manufactured with little to no machining
  • Lightweight parts,die casting is capable of producing parts for industries where weight is a concern,such as the aerospace and automotive sectors
  • Have a good stiffness and strength-to-weight ratio
  • Is more cost-effective than alternative casting processes

DECIDING ON THE BEST DIE CASTING METHOD

Die casting is a very efficient and versatile process used in metalworking, capable of producing countless varieties of parts used in a wide range of applications and industries. However, it is important to take certain factors into consideration when making the decision between pressure and gravity die casting. These factors include:

The batch and quantities required

The complexity and surface finish of the castings

The wall thickness of the components

The type of material you would like to use

The lead time you need for your project

In order to get the right finished product, it is crucial that you make the right selection for your specifications. To find out which process is most suited to your project, get in touch with our experienced team.

 

With BELLYSON we offer a single - source solution in meeting die casting manufacturing requirements. Believe that we can manage the die casting process for you.

We also have several years experience in the die casting process and the manufacturing of aluminium casting and zinc die casting.

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