A reason this guide answers all your questions on high pressure die casting.

So keep reading to learn more.

What Is High Pressure Die Casting?

High pressure die casting is the process of forcing molten metal under pressure into sealed mould cavities.

You will use high pressure die casting to mould different metallic materials under high pressure using true die hydraulic machines.

Which Metal Alloys Are Suitable For High Pressure Die Casting?

High pressure die casting system

Well, there are numerous metal alloys that you can use for high pressure die casting depending on the final materials outcome.

Usually, you will use high pressure die casting for different types of metals which melt at high temperatures.

Here is a list of the common types of metals that you can mold using high pressure die casting method.

• Aluminium Metal Alloys
• Copper Metal Alloys
• Magnesium Metal Alloys
• Zinc Metal Alloys
• Tin Metal Alloys
• Lead Metal Alloys
• Carbon Steels Alloys
• Low-alloyed Steel Metals
• High-alloyed Steel Metals
• Tung-stem Steel Metals
• Chrome-molybdenum Steel Alloys

You can also opt for or use specific die casting alloys such as:

• Zinc Aluminium Metal Alloys to different aluminium association standards such as AA380, AA384, AA386, AA390 and AZ91D Magnesium

When Should You Choose High Pressure Die Casting?

You should choose high pressure die casting method to manufacture metallic moulds at a high speed.

Apart from that, you will choose high pressure die casting to manufacture precise or specific shapes.

In other words, it is the fastest and most reliable method for manufacturing durable and complex shapes.

In addition, you will choose high pressure die casting to accommodate stringent dimensional and appearance tolerance requirements.

As such, high pressure die casting is more suitable for meeting very high-quality moulding standards.

Additionally, you will choose high pressure die casting to achieve perfect and smooth surface finishes which can be textured.

Finally, you will choose high-pressure die casting method to produce relatively small or large metallic parts.

What Are The Disadvantages Of High Pressure Die Casting?

Despite the numerous benefits, you may also encounter a couple of limitations while using high pressure die casting.

As with any other forming process, high pressure casting present limitations that are impractical to specific applications.

Here are some of the limitations of high pressure die casting.

Operation Cost

You will spend relatively high start up and operational costs when using high pressure die casting method.

High pressure die casting dies are usually very complicated to make thus increasing the cost of production.

Slow On Thick-Walled Castings

You will have to slow down when manufacturing thick-walled metal castings using high pressure die casting methods.

The process requires additional time to dry and solidify thick-walled metal castings thus limiting the production speed.

Possibility Of Porosity

You may also run the risk of porosity through the high pressure die casting method due to presence of air pockets.

It may occur when selecting the wrong metal alloys, and during shrinkage of cast materials among others.

Limited To High-Fluidity Materials

You can only use high pressure die casting method on materials or metals that exhibit high fluidity levels.

In the long run, high pressure die casting results in materials that have low strength values than other methods.

High pressure die casting ollustration

How Does Low Pressure Die Casting Compare To High Pressure Die Casting?

You can either use high pressure die casting or low pressure die casting method to fill every crevice in die casting.

Here is a comparison between high pressure die casting and low pressure die casting methods.

High Pressure Die Casting

This is a faster die casting process which involves production of high pressure reaching about 150,000 kPa.

It produces high pressure on the device that enables molten metal to flow at a higher speed on a horizontal setup.

Low Pressure Die Casting

Low pressure die casting uses relatively small applied pressure ranging between 20 to 100 kPa.

It forces molten metal to move vertically into the mold in a slow but gradual climb from the furnace.

What Are The Components Of High Pressure Die Casting Machine?

High pressure die casting machine has numerous or several components that enable the high pressure die casting process.

Here are the main parts of the machine that enables or facilitates the manufacturing process.

High pressure die casting machine

• Casting cavity

The casting cavity is the space between the moving platen and the fixed platen where the molten metal alloy is cast.

• Moving Platen

The moving platen pushes the molten metal into the die cavity and releases it once it forms the right shape.

• Fixed Platen

The fixed platen is part of the die cavity that blocks the molten metal from passing through to the other parts.

It also helps in creating the final shape of the die by maintaining a solid press on the molten metal alloys.

• Injection Piston

The injection piston pushes the molten metal straight into the die cavity.

It produces high pressure that forces the molten metal straight into the die cavity at high speed.

• Ejectors

You will use the ejectors to eliminate or remove the formed die cast from the die cavity.

There are different types of ejectors such as vacuum or pressure ejectors that eliminate the final die cast.

• Die Cavity

The die cavity is the chamber or part of the machine that forms the shape of the final product.

You can have different shapes and sizes of the die cavity depending on the final product specifications.

• Cooling System

The cooling chamber is responsible for eliminating excess heat and solidifying the molten metal.

It uses water as the main cooling agent to eliminate excess heat from the molten metal.

• Feeder Channel

You will use the feeder channel to feed or push the molten metal into the die cavity.

It acts as a gate or a path for the molten metal to flow into the die cavity for moulding.

How Does High Pressure Die Casting Process Work?

You can use the high pressure die casting method or machine to make anything out of metal alloys.

While there are numerous ways of performing high pressure die casting method, there are four main steps to follow.

Here are the four main steps you can follow to successfully operate the high pressure die casting machine.

Step One: Mold Preparation

Firstly, you will begin the process by preparing the mold by lubricating the internal parts of the machine.

You should consider lubricating the internal parts of the machine to regulate the temperatures during the manufacturing process.

Apart from that, the lubricant creates a film between the mold and the molten metal thus facilitating easy removal.

You should also prepare the molten metal alloys using the materials that will suit your final requirements.

As soon as you complete the process, you will power the machine in preparation for the die casting process.

Step Two: Injection Process

Secondly, you will proceed with the injection or introduction of the molten metal alloys after preparing the mold.

At this point, you must make sure that the mold is completely closed and sealed to prevent leakages.

Apart from that, you must close and seal the mold to allow or accept the highly pressurised molten metal.

Depending on the application specifications, you may inject the molten metal into the mold at a pressure between 1500 to 25000 Psi.

The machine will maintain the specific pressure until the molten metal cools and solidifies.

Step Three: Cavity Ejection

As soon as the molten metal alloy solidifies and cools down completely, you will eject it from the mold.

You will engage the ejector pins to release the cavity from the mold.

At this point, the cavity is in a solid form thus facilitating easy ejection from the mold.

All the high pressure die casting machines are programmed to eject the cavity when it solidifies.

Step Four: Shakeout

Finally, you will complete the process of high pressure die casting by conducting a shakeout.

You will remove any scrap metal that may stick to the cavity using different scrapping methods.

It is common for different cavities to accumulate excess scrap metal during the die casting process.

Apart from that, there are other scrap metal pieces that remain within the mold that must be removed.

You will remove all the scrap metal remains within the mold before reusing the mold.

How Can You Increase Efficiency Of High Pressure Die Casting Process Flow?

You can increase the efficiency of the high pressure die casting process flow by making a few adjustments.

Here are some of the methods that you can use to increase the efficiency of high pressure die casting process.

• Quantify Everything

You can increase efficiency of high pressure die casting process by ensuring that all the quantities are properly measured.

A proper mixture of the metal alloys will create a fluid that can flow easily thus boosting process flow.

• Improve Training or Hire Professionals

You should consider hiring trained personnel with plenty of experience in handling the high pressure die casting process.

Apart from that, you can also train the personnel within your reach to improve their skills.

• Weight Reduction

You should reduce the weight of the metal alloys to optimum levels to maximize the flow of the metal alloy.

Apart from reducing weight, you will also save cost in the high pressure die casting process thus boosting production efficiency.

Which Defects Are Common During High Pressure Die Casting Process?

During the casting process, there are possible defects that you may experience.

Here are the common defects and their causes that occur during high pressure die casting process.

• Flash Defect

The flash defect occurs when the injection pressure is very high and the clamp force is too low.

• Unfilled Sections

You may also have unfilled sections due to insufficient shot volume, low pouring temperatures, and slow injection.

• Bubble Defects

It is common to see bubble defects when the injection temperature is too high causing non-uniform cooling rates.

• Hot Tearing Defects

Hot tearing defects are common in the die casting process due to non-uniform cooling rates.

• Ejector Marks Defects

You may also have ejector marks when the cooling time is too short and the ejection force is too high.

How Can You Prevent Defects During High Pressure Die Casting?

Stages in high pressure die casting

Well, you can prevent defects during high pressure die casting process by sorting out the malfunctions.

Here are some of the ways that you can explore to prevent defects during high pressure die casting process.

Controlling And Balancing The Parameters

You can prevent defects such as the flash defect by balancing the injection pressure and the clamp force.

In other words, you will reduce the injection pressure and increase the clamp force.

You can also prevent unfilled sections by increasing shot volumes and speed of injection.

Apart from that, you can increase the pouring temperature to solve the unfilled sections.

You can also balance the cooling rate and reduce injection temperature to eliminate bubbles.

In addition to that, you should control the cooling time and ejection force to eliminate the ejection marks.

Can You Make Complex Parts With High Pressure Die Casting?

Yes, you can make complex parts with the high pressure die casting machine.

It is the most suitable method that will fit every crevice and nuke of the mold thus preventing leakage.

It is capable of accommodating stringent requirements for dimensional tolerance and appearance thus suitable for making complex parts.

Some of the parts that you can make using the high pressure die casting method include:

• Engine Blocks
• Gearbox Casings
• Oil Sumps
• Engine Mounts
• Other Structural Parts

What Is The Recommended High Pressure Die Casting Pressure Range?

You should maintain a recommended high pressure of about 150,000 kPa when using high pressure die casting.

The recommended pressure is high enough to press the molten metal alloys to create the desired shape.

You have to ensure that the pressure is constants throughout the solidification phase to eliminate potential defects.

Apart From High Pressure Die Casting, Which Other Techniques Can You Use To Make Parts?

There are other methods that you can explore to make complex parts, other than high pressure die casting.

Here are the common methods that you should consider exploring when making the high pressure die casting.

·         Squeeze Die Casting Process

You can opt for the liquid forging or squeeze die casting process to combine permanent mold casting with die forging.

It is a single step where specific amounts of molten alloys are poured in lubricated and preheated die.

Finally, it is forged and then solidified under very high pressure to form the desired casting shape.

·         Vacuum Die Casting Process

You can also opt for vacuum die casting process by injecting molten metal under extreme pressure into a steel die.

It has a vacuum assisted system that draws in the short sleeve and mold cavity before injection mold occurs.

·         Semisolid Casting Process

You may opt for the semisolid casting process that combines forging and casting together.

It depends on the sheared flow of thixotropic fluids and solidification while fluid is standing.

How Does Hot Chamber Die Casting System Compare To Cold Chamber Die Casting System?

You can either opt for the hot chamber die casting method or the cold chamber die casting system.

The hot chamber die casting method heats the metal alloys inside the casting machine during the formation process.

In this case, the machine has the heating chamber that heats and melts the metal within the machine.

On the other hand, cold chamber die casting method involves hating the metal alloys outside the machine.

In other words, you will have a separate heating chamber for melting metal alloys before casting on the machine.

How Can You Reduce Cost Of High Pressure Die Casting Process?

You can explore different options to reduce the cost of high pressure die casting process.

Here are some of the tricks that you can explore to reduce the cost of high pressure die casting.

Breaking Don The Cycle Time

You can break down the cycle time into resetting time. Cooling time, and injection time.

After that, you will reduce every time category thus reducing the overall time of production and cost.

Purchasing In Bulk

You can reduce the cost of high pressure die casting process by purchasing all the raw materials in bulk.

In this case, you will factor in the economies of scale to reduce the cost of high pressure die casting process.

Conduct Mold Flow Analysis

Analysing the mold flow will help in identifying the pitfalls within the high pressure die casting process.

You can solve the pitfalls within the process to enable a smooth transition thus reducing the production cost.

Use Core To Lower Mold Costs

You can also use the cores that require minimal modification to reduce the overall cost of high pressure die casting process.

Instead of eliminating or throwing away molds, you can simply modify them thus saving on the cost of new purchases.

Which Value Added Operations Can You Apply On High Pressure Die Cast Parts?

You should apply value added operations on high pressure die cast parts to improve surface finish.

A proper surface finish comes with numerous benefits that increase appearance and functionality of the final product.

Here is a list of some of the value-added operations that you can apply on high pressure die cast parts.

Mechanical Finishing

Mechanical finishing encourages improved appearance, wettability or adhesion, corrosion resistance, chemical resistance, tarnish resistance, hardness, and overall wear resistance.

Decorative Finishing

You should also consider decorative finishing to enhance component appearance with texture, colour, and lustre.

Functional Finishing

You should opt for functional finishing to improve the function ability of the final product.

The most common functional finishes are durable press antistatic, antimicrobial, UV protection, self cleaning, flame retardant, and water repellent among others.

Where Can You Use High Pressure Die Casting?

You can apply the high pressure die casting method to make numerous casts in different industries.

Some of the common industries that depend on high pressure die casting method are:

• Automotive Industry
• Aeronautic Industry
• Mining Industry

What Is The Recommended Tolerance For High Pressure Die Casting?

The recommended tolerance for high pressure die casting will depend on the metal alloys.

For instance, the recommended tolerance for high pressure die casting in aluminium is:

• Standard: +/- 0.010 inch per 1 inch — then +/- 0.001 inch for each additional inch
• Precision: +/- 0.002 inch per 1 inch — then +/- 0.001 inch for each additional inch

For all your high pressure die casting needs, Inox offer perfect solution for you – contact us now.

The post High Pressure Die Casting: The Ultimate FAQ Guide appeared first on Inox Cast.

Whether you want to learn about the benefits, choosing alloy, zinc die casting process, quality inspection or any other information – this guide has all you need.

So, keep reading to learn more.

Why Is Zinc Die Casting Products Better Than Die Casting Aluminium Or Magnesium Parts?

• Zinc die casting has a low melting temperature hence quicker to manufacture compared to aluminium which has a high melting temperature.
• Aluminium alloy is a lightweight while zinc alloy is heavier thus energy efficient and has lower production cost hence is good where weight is less important.

Zinc die casting

• In casting zinc strength is higher than aluminium alloy hence the precision is significantly good and the wall thickness can be reduced.

die casting aluminum

• Zinc alloy lifetime is more durable compared to aluminium alloy which have a maximum life time of 100000 shots.

magnesium parts

Which Zinc Alloys Are Suitable For Die Casting Products?

Here are most common zinc alloys;

Zamak 2

It has a great strength compared to other alloys due to 3% copper increase in it hence making it expensive than others.

Has the same composition as zamak 3 hence composed of magnesium, copper, zinc and aluminium.

Zamak 2

It is used for die casting hence it is also known as Kirk site.

Also used for mandrels for metal spinning.

Zamak 3

It is the most used zamak alloy compared to other alloys.

Composed of 90% zinc ,10% aluminium.

Mostly preferred for die casting.

Zamak 3

Zamak 4

It helps in ductility of zamak 3 hence it reduces the effects of die soldering.

Zamak 4

Zamak 5

It also has same composition as zamak 3 but has addition of 2% copper hence to increase its strength corrosive resistance and hardness.

Zamak 5

Zamak 7

It is used in casting thin wall hence has less magnesium to increase ductility and fluidity.

Nickle is added to it to reduce inter-granular corrosion and more impurities are also controlled.

Zamak 7

What Are The Benefits Of Zinc Die Casting Products?

Here are some of the benefits of zinc alloys;

• Zinc alloys produces a precise and resilient casting with high fluidity when it is molten.
• They are tough and have great rigidity than aluminium counterparts.
• Die casting zinc alloys are stronger hence they can be produced with thinner walls and less material to optimize strength compared to other materials like plastics and aluminium.
• Another advantage is that zinc alloys have a lower melting temperature hence it can last 20 times longer than aluminium alloy.
• When using zinc alloys, they provide a decorative and a great adhesion of any finish to its substrate thus these finishes are corrosion resistance.
• Zinc alloys also allows surfaces to act as brushings for structures in motion since they have good waring and bearing properties.
• They are also 100% recyclable hence all the by-products of the casting process can be remelted and cast again without degradation.
• Its fluidity provides increased precision hence allowing designs that do not require additional expensive machining.
• They are cost effective since they solidify rapidly in lower melting temperature thus producing more parts in the same amount of time.

Why Is Hot Chamber Die Casting Suitable For Zinc Die Casting Products?

Hot chamber die casting is suitable because it uses alloys with low melting temperatures like zinc alloys hence to avoid damage to gooseneck and other components.

hot chamber die casting

What Are The Benefits Of Hot Chamber Zinc Die Casting Products?

• The casting cycles are shorter hence has a higher production capacity.
• It offers longer tool life since it utilizes low melting point alloys which has less impact on the die.
• Hot chamber is more efficiency due to the machine containing an internal melting pot.
• It has less wasted metal hence it is more environmentally friendly.
• Reduced porosity.

Are There Limitations Of Hot Chamber Zinc Die Casting Products?

• In hot chamber die casting cannot fully heat since there are pores on the surface hence it will lead to formation of blisters on the surface of the metal.
• It offers limited metal fluidity due to variance in alloy malleability hence limiting the final products shape.
• Hot chamber is only cost effective if you have a high volume of products that need to be produced.

What Are The Components Of Hot Chamber Die Casting Machine For Zinc Products?

The following are parts of hot chamber;

• The injection
• The furnace.
• The plunger.
• Ejector pins.
• Ejector dies.
• gooseneck

How Does Hot Chamber Zinc Die Casting Products Work?

The hot chamber system is used with metals such as; magnesium, lead and zinc.

The furnace on the machine is attached by a metal feed system called gooseneck where the injection process of a hot chamber is thrust in the molten metal.

Then molten metal is then allowed to fill the cylinder by closing the die and piston rising to open the port.

The molten metal is then pushed through the gooseneck and nozzle into the die cavity when the plunger seals the port hence it is held under pressure until it solidifies.

When the die open, the molten metal flows back through the nozzle and the gooseneck hence the casting remains in the ejector side.

Then ejector pin pushes the casting out of the ejector die thus the molten metal flows through the inlet to refill the gooseneck.

Which Temperature Is Best For Zinc Die Casting Products?

The parts are melted at the temperature of about 380-420c adjacent to the die casting machine hence the alloy is injected into a mould.

When the melting temperature is too low, the flow property will be poor hence it will affect the surface quality of the zinc die casting.

When the temperature is high, the casting crystallization is good and mechanical performance is reduced.

Is High Pressure Necessary For Zinc Die Casting Products?

Absolutely yes.

High pressure die casting involves;

Preparing The Mould.

At this stage the lubricant is applied to the interior walls of the mould hence to regulate the moulds temperature and for easier removal of casting.

Injection.

After preparing the mould, the molten metal is then injected in it when the mould is tightly sealed and closed.

The mould has to maintain the pressure until molten metal has cooled and solidified.

Cavity Injection.

The new cavity from the mould is then ejected by the manufacturing company using automatic ejector pin.

This process cannot be accomplished if the cavity is still liquid hence it has to be solid for it to eject.

Shakeout.

At this final stage, any excess scrap metal is separated from the new cavity before the mould can be reused.

The moulds are durable hence more parts can’t be manufactured to decrease the number of components requested.

The fusion has a good surface finish thus reducing the thickness of the plate walls hence reducing the overall weight of the fusion.

It has a higher production speed when compared to the flow pouring under the effect of gravity.

High pressure has the ability to produce flows of specific dimensions hence to re3duce processing operations.

Which Defects Are Common During Zinc Die Casting Products Process?

Zinc die casting alloy has many sources to cast defects hence here are some of the common defects, causes and their remedies;

Cracks.

Cracks appears when a metal does not have sufficient strength to resist tensile force during solidification.

To avoid cracks, set die coat spray properly in proper mixture hence maintain die temperature within limit by setting die open time.

Blisters.

With high die temperature, a thin film of small surface blows up on the surface of the component.

Proper flow of die coat spray is usually maintained to prevent blisters hence proper mixture of die coat chemical is done.

Blow Holes.

This occurs when there is no proper venting hence the metal can’t hold as much gas as the fluid form.

It is prevented by proper venting thus set spray for adequate amount of die coat.

Pin Holes.

It is also known as porosities.

They are usually found on the upper part of the mould in poorly vented pockets hence they appear in large numbers at the surface of the casting.

Fusion.

It adheres to the casting thus it is thin with brittle and glassy appearance hence occurs when sand grains fuse with molten metal.

Swells.

This are enlargement of the casting hence they are smooth bulge on the vertical face of the casting.

Drops.

This occurs when the metal is still in liquid hence when the pieces of sand fall into the metal casting.

Metal Penetration.

During the moulding sand the liquid metal penetrates in the gaps hence they are rough and uneven surface finish of the casting.

Warping.

This can happen during or after solidification hence they change in the dimensions of the final product.

Mismatch/Shift.

It is a horizontal displacement of a metal hence it is due to misalignment of upper and lower part of the mould.

How Can You Eliminate Defects Of Zinc Die Casting Products?

• Maintain die temperature within limit by setting die open time, die open and close speed properly.
• Check and maintain injection pressure and maintain oil pressure.
• Provide proper venting.
• Check and maintain continuous cycle time and die opening time.
• Check and open choked die cooling.
• Insert internal chills, cooling ribs to increase local heat dissipation.
• Limit the total volume deficit by reducing casting temperature.
• Inspect and replace any defective moulds before casting.

How Do You Check Quality Of Zinc Die Cast Products?

Destructive Test.

This test is used to detect the porosity during the casting period hence the porosity can weaken the integrity of the final part.

Visual Test.

This is established by the customer by looking hence a piece of zinc may not look right visually thus it may require retooling.

Leak Test.

This is done using an air decay leak tester hence to detect if the casting is leaking due to porosity and worn-out dies.

Poke Yoke Method.

The method is used to detect poor trimming process by leaving excess material on your part. The procedure helps you prevent poor die cast maintenance and poor design

Are Zinc Die Cast Products Strong?

Absolutely yes.

The parts provide a greater impact of resistance to shocks, wear and corrosion compared to other alloys hence they are versatile in finishing the articles.

Its ductility and good strength allow to have flexibility in the design of small parts and details.

They are tough and have great rigidity than aluminium counterparts.

zinc die cast

Die casting zinc alloys are stronger hence they can be produced with thinner walls and less material to optimize strength compared to other materials like plastics and aluminium.

They are also 100% recyclable hence all the by-products of the casting process can be remelted and cast again without degradation.

Its fluidity provides increased precision hence allowing designs that do not require additional expensive machining.

Where Can You Use Zinc Die Cast Products?

Zinc die cast products can be used in;

• Power steering system.
• Electronic devices.
• Brake parts and systems.
• Fuel system.
• Interior automotive aesthetic parts.
• Air-conditioning systems and components.

Will Zinc Die Cast Products Rust?

Yes, zinc rust when exposed to air and moisture.

They offer corrosion resistance hence when they react with oxygen to form a thin oxide layer which reacts with moisture to produce zinc hydroxide.

It works best for the application that are not based to high temperatures due to its smooth surface finish.

Zinc rate of corrosion is 1/30 that of steel hence metals coated with zinc-based products have a longer life time when exposed to atmosphere.

When the zinc surface has not fully developed the protective carbonate layer, it exhibits a corrosion known as white rust.

It occurs when there is lack of free air over the zinc surface hence the white rust is powdery in appearance.

How Does High Pressure Zinc Die Casting Products Work?

High pressure die casting involves;

Preparing The Mould.

At this stage the lubricant is applied to the interior walls of the mould hence to regulate the moulds temperature and for easier removal of casting.

Injection.

After preparing the mould, the molten metal is then injected in it when the mould is tightly sealed and closed.

The mould has to maintain the pressure until molten metal has cooled and solidified.

Cavity Injection.

The new cavity from the mould is then ejected by the manufacturing company using automatic ejector pin.

This process cannot be accomplished if the cavity is still liquid hence it has to be solid for it to eject.

Shakeout.

At this final stage, any excess scrap metal is separated from the new cavity before the mould can be reused.

high pressure zinc die cast

Why Choose High Pressure Zinc Die Casting?

The moulds are durable hence more parts can’t be manufactured to decrease the number of components requested.

The fusion has a good surface finish thus reducing the thickness of the plate walls hence reducing the overall weight of the fusion.

It has a higher production speed when compared to the flow pouring under the effect of gravity.

High pressure has the ability to produce flows of specific dimensions hence to reduce processing operations.

The process is cost effective since the casting cycles are short compared to other methods as the molten metal solidifies quickly.

It is good when creating lightweight casting since the casting can produce wall thicknesses as low as 1mm.

Are There Limitations Of High Pressure Zinc Die Casting?

It has casting porosity hence can be caused by selecting the wrong alloy for the cast but evacuated chamber may reduce this.

The components created through high pressure cannot be fully heat treated due to the presence of pores which will lead to formation of blisters.

When compared to gravity die casting, it is considered inflexible.

When using high pressure die casting  a large capacity investment is needed for the set up.

High pressure die casting uses complex and expensive equipment.

The dies are usually costly hence high pressure die casting costs are only considered with high-volume production runs.

Which Surface Finishes Do You Use After Zinc Die Casting Products?

• Polyester powder coatings.

Dry electrostatic process is used during this coating as powder hence solvents are not used to prevent the formation of solvent caused defects.

• Sprayed coatings

it involves different chemistries like polyester, phenolic and epoxies.

• Zinc black.

This process helps in corrosive environment hence a thick black phosphate is conferred to the casting.

• Copper-tin-zinc electroplate.

The coating turns the finish to black though it gives zinc a correct protection thus it is dull and silvery on the zinc surface.

• Galvanize coating.

This coating help to protect the metal from corrosion and improves the appearance of the surface.

The desired appearance is achieved only by selecting chromium [111] containing passivation such as black passivation, thin film passivation and thick film passivation.

• Black oxide.

It protects metal from corrosion hence it acts as an absorbent to hold oils.

It has a uniform black finish that is used to sport spark plugs, furniture brackets where a black surface is needed.

Black oxide provides a variety of valuable [properties hence improving the performance characteristics of a component.

• Black chromate with zinc.

This type of coating is applied over zinc plating during the surface coating process.

It corrodes before the base metal hence it is a corrosion resistant finish, ductile and soft.

• Electroless nickel.

Electroless nickel provides deposit properties within deep recesses and blind holes hence they give good corrosion, wear and abrasion resistance, electrical properties and hardness.

We have three types of electroless nickel which are;

• Low phos.
• Mid phos.
• High phos.

• Black E-coat.

It is an electrically applied paint coating thus it is used in decorative that enhances the appearance of parts hence also protecting the surface of parts.

• Black anodizes.

Black anodize particles are boiled in a solution of nickel acetate to produce non-conductive protective coating.

This helps to achieve adequate corrosion resistance thus sealing the component effectively.

Is Cold Chamber Zinc Die Casting Products A Perfect Die Casting Alternative?

This is used for metals that have high melting point such as; copper, zinc alloys, brass and aluminium alloys.

The molten metal is ladled into the cold chamber shot sleeve and the die closes.

The plunger then pushes the molten metal into the die cavity where it is held under pressure until it solidifies.

cold chamber zinc die casting

The casting remains in the ejector die while the die opens and plunger advances hence the ejector pin push the casting out of the ejector half of the die.

For all your zinc die casting products from China, contact us now.

The post Zinc Die Casting Products: The Ultimate FAQ Guide appeared first on Inox Cast.

A reason this guide will answer all your questions on die casting manufacturing processes.

So, before choosing a die casting process, read this guide.

What Is Die Casting Manufacturing Process?

Die casting manufacturing process is a technique where you will pour or force molten metal into moulds.

It allows you to make geometrically complex metal components through the use of these molds.

The moulds are also known as dies or tools and are mainly fabricated from steel with unique designs for every application or project.

This enables you to manufacture the components or parts with a high level of accuracy and consistency.

What Are The Benefits Of Die Casting Manufacturing Process?

The die casting manufacturing process has several benefits over other types of manufacturing processes.

This allows you to save both on the overall production cost and the price of the components.

When you cast components, you can form complex shapes, entailing external threads and internal traits with minute draft angles.

This allows you to spend less on secondary processes.

Also, you can combine several components into single parts thereby removing assembly-related operations and minimizing labor costs.

Here are some of the other benefits of the die casting manufacturing process:

Time-saving

The die casting manufacturing process is a way that you can use to increase the production speeds in your industry.

Whether you are using pressure or gravity die casting manufacturing process, it will save you lots of time.

This means you can meet your market demands within a short time when using the die casting manufacturing process.

Cost-efficient

The die casting manufacturing process offers suitable choices for the processing of your material metals.

Besides, it allows you to lower the production costs and enables your clients to enjoy this benefit at the end of the production chain.

Enhances Metal Strength

The products you make via the die casting manufacturing process are much stronger than other treatment options for metals.

Besides, die casting manufacturing process maintains the quality of the components.

For instance, your metals will degrade if you plan to use injection moulding processes.

Also, it adds extra value to the metals you are using in your application.

Accurate

The die casting manufacturing process is very accurate which is why several industries are using it.

Besides, the final component or part has stable and accurate designs.

Furthermore, you can make a product that will meet your specification requirements through the use of the die casting manufacturing process.

Various Finishes

A complete die casting manufacturing process has room for adding different versions of metal finishes.

Besides, you can adjust the process to meet your requirements like plated, galvanized, or coated metal finishes.

Inserts

The die casting manufacturing process can include bearings, threaded inserts, or add-ons.

Minimal Assembly

Die casting manufacturing process can include studs, bosses, or drill holes within the design of the mold.

High Reliability

The die casting manufacturing process allows you to make large amounts of components uniformly.

Tensile Strength

The parts you make using die casting manufacturing process have a tensile strength of 415 MPa or 60000 PSI.

Tolerances

The die casting manufacturing process enables you to fabricate complex components with very high tolerance levels.

Automation

To increase the efficiency and lower the cost of the die casting manufacturing process, you can use pneumatic and hydraulic devices.

What Are Some Disadvantages Of The Die Casting Manufacturing Process?

Here are some limitations to using the die casting manufacturing process:

Cost

All moulds you use in the die casting manufacturing process need to be precisely made.

This means you will spend more time shaping and crafting the moulds.

Furnaces

The furnaces you use in the die casting manufacturing process reach thousands of degrees.

This means you will consume a lot of energy and produce pollutants that you need to filter before releasing them.

Metals

The die casting manufacturing process can only handle metals that have a high rate of fluidity.

This will influence the components you can fabricate.

Dies

The dies you make for the die casting manufacturing process are costly, made of durable stainless steel, and you cannot adjust them.

Labor Intensive

It is important to closely monitor and manage the die casting manufacturing process, especially in the cooling stage.

Defects

Some of the defects you can encounter include metal pouring, shrinkage, or porosity.

Which Metals Will You Use In The Die Casting Manufacturing Process?

The most common metals you will use in die casting manufacturing process include the following:

Zinc Alloy

This is a common metal that is widely used in different applications in today’s world.

Furthermore, you need to understand the different zinc alloys before choosing the one suitable for your application.

Some of the most common zinc alloys you will find include Zamalak alloy and ZA alloys.

Besides, zinc is suitable material since it can withstand high temperature and pressure levels.

Using this process, zinc alloys and metal find their applications in several areas.

Brass Alloy

This alloy is a combination of zinc and copper metals.

Besides, there are different types of brass alloys, which come about due to the different levels of zinc and copper.

Furthermore, you can add other metal materials in brass to improve their characteristics to desirable levels.

Examples of brass alloys you can use include the following:

1. Alpha brass
2. Aluminum brass
3. Admiralty brass
4. Beta brass
5. Duplex brass

One main advantage of a brass alloy is that it is simple to machine.

Brass metal alloys are easy to use in the die casting manufacturing process.

Besides, brass has a high level of strength and is highly resistant to corrosion, which adds to its benefits.

Also, it has a low melting point, thus, it is easy to work with during the die casting manufacturing process.

Aluminum Alloy

One of the most common metals you will use in the die casting manufacturing process is aluminum.

Besides, aluminum is affordable and has been used for a very long time.

Also, aluminum metal has suitable strength levels making them suitable for different application ranges.

Aluminum is also recyclable and it is a suitable metal to manufacture into usable components or parts.

There are different types of aluminum alloys and they include:

1. B390 alloy
2. K-alloy
3. Alloy 383
4. B360 alloy
5. Alloy 413, etc.

Some of the benefits of aluminum metal that make them suitable for the die casting manufacturing process include the following:

1. High operating temperature
2. Tenacity
3. Lightweight
4. Suitable thermal properties, etc.

Steel Alloy

This is also another metal you can use in the die casting manufacturing process as it is extremely versatile.

For this reason, you can use steel in several applications.

Steel is an alloy of both iron and carbon, and this means it contains similar properties as these two elements.

This makes steel metal contain several excellent performance characteristics.

Besides, you can find the following components within steel:

1. Tungsten
2. Vanadium
3. Chromium, etc.

Some examples of steel you can use in die casting manufacturing process include:

1. Carbon steel
2. Alloy steel
3. Tool steel
4. Stainless steel

Steel also has favorable characteristics that make them suitable for the die casting manufacturing process.

These entail:

1. Recyclability
2. Extra strength
3. Thermal conductivity
4. Corrosion resistance
5. Electrical conductivity
6. Lightweight

Copper Alloy

Die casting manufacturing process can use copper-based alloys.

Copper alloys are durable thus effective for mechanical products.

Since copper has high levels of resistance against corrosion, they are suitable for electrical and plumbing applications.

Magnesium Alloy

This metal has a high strength-to-weight ratio even though it is a light alloy.

Magnesium is suitable for applications needing tight precision and thin-wall structures.

What Are The Types Of Die Casting Manufacturing Processes?

The three main types of methodologies you can use in die casting manufacturing process entail the following:

Pressure Die Casting Manufacturing Process

High pressure die casting process

This process is good or high-volume run components.

It can produce components with thin walls while maintaining their quality.

Besides, different die casting machines ranging between 80 and 1100 tons are used as it depends on the pressure you need.

The pressure die casting manufacturing process uses external pressure to force molten metal within different moulds.

There are two categories under this type, that is, low pressure and high pressure die casting.

They all rely on the amount of pressure you will use in the die casting manufacturing process.

Some benefits of pressure die casting manufacturing processes include the following:

1. This process can manufacture parts that possess high mechanical characteristics.
   That is, the components contain suitable finishes and tight dimensional accuracy.
   For this reason, you will use it to manufacture intricate machine components.
2. The process is suitable for producing components on a large scale.
   This is because the pressure will increase the molten metal rate of flow.
   However, it is not suitable for use in short production processes because it has high setup costs.
3. It maintains the purity of the final product.
   The final component is free from the effects of oxidation as there is no gas within the metals.
4. The pressure die casting manufacturing process is more economical than other casting methods.
   This proves to be correct when you are applying it in large production runs.
   Besides, you can manufacture components in the thousands before considering replacing the parts of the machine.
5. Depending on the amount of pressure that you apply, you can easily control the dimension of the product outcome.
6. The pressure die casting manufacturing process is suitable for casting metals that are lightweight and have thin walls.

Some limitations of the pressure die casting manufacturing process include the following:

1. The process is conducive to producing components in large amounts.
2. Because of the technology in the system, the initial cost is usually high.
3. The pressure die casting manufacturing process is suitable for metal parts with high fluidity levels.

Gravity Die Casting Manufacturing Process

Gravity die casting

This process is suitable for use in the manufacture of components in medium to high production runs.

Besides, it will use permanent moulds under normal situations making it possible to attain a near-net-shape component.

The gravity die casting manufacturing process can either be automatic or manual.

Also, the weight of the outcome component depends on the type of gravity die casting machine you are using in your application.

This process is widely accepted in several industries because it lowers the production cost.

Besides, gravity die casting manufacturing process tooling cost less than those for high-pressure die casting manufacturing processes.

Let us consider the operational principle of the vacuum die casting manufacturing process.

The gravity die casting manufacturing process operates by relying on gravity and not pressure.

There is no force that you will apply to enable the molten metal to flow in this process.

Furthermore, you will use this process to cast non-ferrous alloys such as zinc, copper, and aluminum.

Also, you will use this process to manufacture heavy metal parts.

However, the components you produce using this process are thinner than those you manufacture through sand casting.

There are four main processes you will employ during the gravity die casting manufacturing process:

1. The first step entails heating the mould, then spraying with lubricants, and finally closing the unit.
   Lubricants are important as they assist in controlling the temperature of the mould.
2. Pour the molten metal into the mould and allow it to cool.
3. Opening the die to eliminate the metal cast part with the assistance of ejector pins.
4. Preparing the die for the upcoming casting process.

The gravity die casting manufacturing process allows you to make parts with complex shapes.

Some parts you can manufacture using this process include the following:

1. Diesel engine components
2. Cylinder components
3. Air conditioning units
4. Valve flow units, etc.

The benefits of the gravity die casting manufacturing process include the following:

1. The dimensional accuracy is better.
2. It minimizes the secondary operations that you can perform.
3. With the assistance of undercuts, you can make undercuts.
4. It is possible to attain a fast production rate.
5. The surface of the final components is smoother than those from sand casting.
6. It can produce thin walls.
7. The process adds to the mechanical properties of the metal such as high tensile strength.

The limitations of the gravity die casting manufacturing process entail the following:

1. A high initial cost.
2. It can only attain a minimum wall thickness value that ranges between 3 mm and 5 mm.
3. The process does not support the manufacture of very complicated shapes.

Vacuum Die Casting Manufacturing Process

Vacuum die casting

This process is being employed by industries that are manufacturing large components.

Normally, large components tend to have issues with porosity as the air gets trapped in the part during the casting process.

However, the vacuum die casting manufacturing process proves to be suitable for solving the porosity issues.

Let us have a look at how the vacuum die casting manufacturing process operates.

In several situations, you will manufacture the die from steel material in airtight bell housings.

Molten metal will enter the vacuum and die via two receivers, that is, the sprue and the outlet top.

When there is a pressure difference, the molten metal will flow up the sprue and into the die where it will solidify.

This process happens repeatedly.

When you vary the vacuum between the cavity and molten metal, you can control the pressure differential in this system.

Also, this process needs tight control units which you can attain in the process design.

The automotive industry relies on this method to manufacture a variety of engine components.

The benefits of the vacuum die casting manufacturing process include:

1. Die cast components contain suitable welding traits.
2. Vacuum die casting has low production scatter.
3. Components contain high mechanical strength.
4. The die will produce accurate components that may do without secondary processes.
5. It is superior at minimizing gas porosity.

The limitations of the vacuum die casting manufacturing process entail:

1. It has a high initial setup cost.
2. The process of setting up this process is difficult.
3. Some components may need secondary processes as they may fail to be highly accurate.

Consider the following aspects when you want the vacuum die casting process to be successful:

1. The vacuum part needs to be of high quality for you to attain high performance.
   Properly seal the die and the shot assembly to ensure reliability and efficiency.
2. Control the velocity and pressure profiles to produce high precision and reproducibility.
3. Ensure you control the following parts: plunger lubrication, die control temperature, die spraying, molten metal fees.

How Does High Pressure And Low Pressure Die Casting Manufacturing Processes Compare?

Here is how these two compare:

High Pressure Die Casting Manufacturing Process

In this manufacturing process, you will inject the molten metal into a metal due to very high pressure levels.

This process occurs under extremely high pressure and velocities.

In most applications, during the die casting manufacturing process, temperatures are normally about 700°C.

Some benefits of high pressure die casting manufacturing process include:

1. It is suitable for the production of parts in large volume
2. It is highly flexible and ensures quick delivery
3. Allows you to attain components with tight tolerance levels
4. It enables you to make lightweight parts
5. Guarantees a high production rate for metal components
6. It can manufacture complex components
7. The final product has a superior finish as they have smooth finishes
8. It can make components with small thickness levels
9. The process is precise as you require minimal to no machining

The limitations of high pressure die casting manufacturing process include:

1. Tooling costs are higher than that of the gravity die casting manufacturing process
2. The casting size is determined by the size of the machine
3. It may require you to use complex machinery
4. Not economical for use in the production of products on a small scale

High pressure die casting manufacturing process

Low Pressure Die Casting Manufacturing Process

In this process, you will inject the molten metal into the cavity at low-pressure levels.

Also, the die cast components you manufacture using low pressure die casting manufacturing process are better than those from gravity die casting.

However, high pressure process produces higher quality than those you manufacture from a low-pressure process.

Low pressure die casting manufacturing process is suitable for casting metals that have a low melting point such as aluminum and magnesium.

The pressure you require to sustain this process ranges between 2 PSI and 15 PSI.

This pressure will cause the molten metal within the furnace to rise upwards in a tube then enter the die cavity.

low pressure die casting manufacturing process

Once the molten metal solidifies, you will release the air pressure.

Some benefits of low pressure die casting manufacturing process include:

1. This process works well when you are producing products in small quantities.
2. It is difficult to attain components with thin walls.
3. This process will guarantee high yields of about 90%.
4. It has enhanced linear tolerance than that of gravity die casting.
5. The process allows you to heat treat the casting.
6. It allows you to attain a high metal component production capacity.
7. The production cost is lower than that of high pressure die casting process.
8. It enhances the surface finish thus minimizing secondary operations.

Some limitations of low pressure die casting manufacturing process entail:

1. The process needs costly and complex equipment.
2. Tooling costs are higher than other processes like gravity die casting.

How Does Cold Chamber And Hot Chamber Die Casting Manufacturing Processes Compare?

This is how these two processes compare:

Hot Chamber Die Casting Manufacturing Process

This process will use metal alloys that have low melting points.

The dies of the hot chamber die casting manufacturing process have two parts, the fixed portion, and the movable portion.

In this process, you will hold the molten metal in open containing pots that connect to combustion furnaces.

hot chamber die casting

It is from here that the molten metal will enter the holding point.

Cold Chamber Die Casting Manufacturing Process

In this process, you will transfer the molten metal using a ladle either manually or automatically to shot sleeves.

cold chamber die casting

Actuation within the injection pistons will force the molten metal to enter the die.

This process will lower contact time between the injector parts and the hot molten metal, thus assisting in enhancing their operating life.

What Tooling Can You Use In Die Casting Manufacturing Process?

These include:

Multi-slide Tooling

The benefits of a multi-slide tooling mechanism include the following:

1. First time overall or net shape
2. It will remove secondary functions such as machining and assembly
3. Also, it ensures minimum part-to-part variety when you compare it to conventional multi-cavity dies
4. It can achieve tight tolerance levels and complex configurations at higher speeds
5. The tooling is compact and will minimally encounter parting-line variation and the unwanted effects on the final component tolerance dimension

Conventional Tooling

This tooling can have either a multiple or a single cavity design.

The tooling is made to lower secondary operations and be efficient, thus lowering production costs.

Other advantages of conventional tooling include:

1. The production is efficient as the water and cooling lines are properly planned
2. To enhance the durability of the tooling, it contains steel-braced dies
3. It achieves net-shape die casts and the design focuses on avoiding secondary operations
4. The design of the die is efficient enough to manage production in high volumes

What Is The Process Cycle That You Will Perform During Die Casting Manufacturing Process?

There are different types of die casting manufacturing processes you can perform.

The steps you will conduct entail the following:

Preparation

Before you start any die casting manufacturing process, you need to prepare the die.

This stage entails heating the die then spraying the surface with a lubricant or refractory coating.

The lubricant maintains the temperature of the die during the die casting manufacturing process.

It also inhibits premature solidification of the cast and assists in removing the component after it has been set.

Afterward, you will tightly close and clamp the die halves.

Injection

This stage will be determined by the type of die casting manufacturing method you are using for your application.

After preparation, you will transfer the molten metal to the die either manually or automatically.

For instance, you can use pressure, vacuum, or gravity die casting techniques in this process.

Cooling

Once the molten metal is within the die cast, you will leave it to cool and solidify.

Before you remove the clamp, allow ample time for the metal to set and attain the shape of the mould.

Furthermore, you will experience irreversible defects should you remove the die cast before time.

Ejection

In this stage, you will unclamp and open the die halves after the cool time has elapsed.

Thereafter, you will carefully remove the cast component.

This can happen manually or with the use of ejector pins that will safely push the cast from the die casting machine.

Trimming

This is the last step you will undertake following the die casting manufacturing process.

As the metal component continually cools, you will scrap metals such as sprues, gates, runners, and flash from the cast.

Also, you can use special tools to remove surplus material and sharp edges.

This allows you to attain the suitable shape of the die cast, then you will clean the part before packing and shipping.

How Does Heat And Pressure Determine The Metal You Will Use During Die Casting Manufacturing Process?

Die casting manufacturing process is not usable with all metal types as they have varying chemical and physical properties.

Since die casting manufacturing process applies heat and pressure, you can only use it on select metals that can withstand it.

Here is how heat and pressure influence the metal choice for your die casting manufacturing process:

Heat

When performing the die casting manufacturing process, you need to apply ample heat to metals to melt them.

Furthermore, the heating process should retain suitable traits of the metal alloy.

This means that the properties of the metal you are using should remain constant even at high-temperature levels.

Pressure

The metal you are using needs to retain its desirable characteristics even under the pressure you will be applying.

What Are The Applications Of Die Casting Manufacturing Processes?

Since you can use various metal alloys in this process, their application is very broad.

Some of the uses of this process entail the production of the following:

• Medical equipment
• Instrumental components
• Manufacturing industries
• Processing industries
• Aerospace industries
• Automotive industries
• Chemical processing industries
• Decorative industries
• Electrical industries
• Plumbing industries

What Types Of Dies Can You Use In The Die Casting Manufacturing Process?

The different types of dies you can use include:

Single Cavity

These can produce single units and are suitable for machines that can handle one die.

Multiple Cavity

These can produce several units of similar components in one casting process.

Combination

This is a form of multiple cavity but instead of manufacturing similar components, it can produce various parts that will fit together.

Unit

These are dies you can insert in larger dies.

The large die is fixed and you can vary the unit to make various parts.

What Should You Consider When Selecting Metals For The Die Casting Manufacturing Process?

These include:

Mechanical Properties

These properties include:

1. Tensile strength
2. Elongation
3. Yield strength
4. Hardness
5. Impact strength

Physical Properties

This entails understanding the metal behavior when you subject it to harsh environmental conditions.

These include high temperature or pressure levels.

Material Composition

This entails understating the composition of the individual metal elements and their applications.

What Should You Consider When Designing Parts Using The Die Casting Manufacturing Process?

These include:

Application

This entails understanding where you are to use the component, for instance, for cosmetic or structural function.

Appearance

Consumers usually take interest in external appearance therefore you need the part to be visually appealing.

This entails planning on the surface finish for your application.

Assembly Technique

The assembly process can be complicated or simple depending on the complexity of the components.

Besides, you can segment and assemble the parts using the following methods:

1. Welding
2. Fastening
3. Cored holes
4. Threading, etc.

Cost

The budget you have will affect the design you can attain.

Make sure the budget does not affect the quality of the final product.

What Factors Will You Consider When Buying Machines For The Die Casting Manufacturing Process?

These include the following:

Ton Capacity

These machines range from 80 tons or more and rely on the application.

Hydraulic System

These parts assist in the movement of different parts such as relief valves, vane pumps, accumulators, etc.

Die Locking System

Most machines use hydraulic units and they need to be adjustable to contain different types of dies.

Heat Exchanger Unit

It operates by cooling the system and inhibiting moulds from overheating.

Machine Base

This is the part where the entire machine will sit, therefore, it should be strong.

Electrical Unit

They are vital for hydraulic machines and consist of motors, relays, switchgear, etc.

Injection And Ejection Unit

They operate using hydraulic units getting power from high-pressure accumulators.

Are Die Casting Molds Important In The Die Casting Manufacturing Process?

Yes.

They contain channels where the molten metal will flow and attain the desired shape.

Also, the mould design depends on the shape you need to attain for your final product.

What Are The Die Casting Mold Component To Consider During The Die Casting Manufacturing Process?

These include:

Die Draft

They minimize shrinkage and allow easy removal of cast components.

Parting Line

It connects moulds and should be free of deformations to ensure uniform moulding.

Fillets

They are smooth concave surface junctions on the corners of the moulds allowing easy removal of cast parts.

Ribs

They enhance material strength, minimizing cracking stress and improving fill capacities.

Symbols

These include logos, brand names, or usage instructions.

Bosses

They act as mounting points when designing the moulds.

Windows And Holes

They allow easy removal of die cast components.

Additional Resources:

High Pressure Die Casting Process

Gravity Die Casting Process

Vacuum Die Casting

Hot Chamber Die Casting

Cold Chamber Die Casting

For any questions or inquiry about die casting manufacturing process, contact us now.

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