Die-Cast Aluminum, Copper, Stainless Steel Parts

Die casting is a die casting part: Using the pressure casting machine with the casting mold installed, the metal such as copper, zinc, aluminum, stainless steel or aluminum alloy heated to a liquid state is poured into the casting mold of the die casting machine for die casting. Casting copper, zinc, aluminum or aluminum alloy parts of the shape and size limited by the mold, such parts are often referred to as die casting parts. Die-casting parts are called differently in different places: such as die-casting parts, die-casting aluminum, die-casting zinc parts, die-casting copper parts, aluminum alloy die-casting parts, etc.

Characteristics of Die Castings

Because the metal copper, zinc, aluminum and aluminum alloy have good fluidity and plasticity, and the casting process is cast in a pressure die-casting machine. Therefore, aluminum die castings can be made into various complex shapes, as well as cast products with higher precision and smoothness. Thereby, the machining amount of the casting and the casting allowance of metal copper, zinc, aluminum or aluminum alloy are greatly reduced. It not only saves electricity and metal materials, but also greatly saves labor costs; Copper, zinc, aluminum and aluminum alloys have excellent thermal conductivity, small specific gravity and high machinability; As a result, die castings are widely used in: Automobile manufacturing, internal combustion engine production, motorcycle manufacturing, motor manufacturing, oil pump manufacturing, transmission machinery manufacturing, precision instruments, landscaping, electric power construction, architectural decoration and other industries.

quality of die castings

The control of the surface temperature of the die-casting mold is very important for the production of high-quality die-casting parts. Uneven or inappropriate mold temperatures can also lead to dimensionally unstable castings. During the production process, the castings are pulled out and deformed, resulting in defects such as thermal pressure, mold sticking, surface depressions, internal shrinkage cavities and thermal bubbles. When the temperature difference of the mold is large, the variables in the production cycle, such as filling time, cooling time and spraying time, have different degrees of influence.

Frequently Asked Questions about Die Castings

The die casting part is not formed and the cavity is not full
cause:
1. The temperature of the die-casting mold is too low;
2. The temperature of the molten metal is low;
3. The pressure of the press is too small;
4. The metal liquid is insufficient; the injection speed is too high;
5, the air can not be discharged.
Adjustment method: 1- 2. Increase the temperature of die-casting mold and molten metal;
3. Replace the high pressure die casting machine;
4. Add enough molten metal to reduce the injection speed and increase the thickness of the feeding port.

Design specifications for die castings

The design of die-casting parts must take into account the wall thickness of the die-casting parts, the casting fillet of the die-casting parts, the draft angle, and the reinforcing ribs;
Casting holes on die castings;
Minimum hole-to-edge distance, oblong holes and slots on die castings, inserts in die castings, machining allowances in die castings, etc.

Specification for fillet design of castings
Usually, the intersection of each part of the die casting should have rounded corners (except the parting surface), which can make the metal flow smoothly when filling, and the gas can be easily discharged, and can avoid cracks caused by sharp angles. For die castings that require electroplating and finishing, rounded corners provide a uniform coating to prevent paint build-up at sharp corners. The fillet radius R of the die casting should generally not be less than 1mm, and the minimum fillet radius is 0.5mm.

Specification for Design of Inserts in Die Castings

First of all, the number of inserts on the die casting should not be too much; Secondly, the connection between the insert and the die casting must be firm, and at the same time, grooves, protrusions, knurling, etc. are required on the insert; Again, the insert must avoid sharp corners for ease of placement and to prevent stress concentrations in the casting. If there is serious galvanic corrosion between the casting and the insert, the surface of the insert needs to be protected by plating; Finally, heat treatment should be avoided for castings with inserts to avoid volume changes caused by the phase transition of the two metals, loosening the inserts.