What is Die Casting?

author: YITECH

2024-10-10

Do you know what is die casting? We could provide you the die casting service. Die casting is a manufacturing process that injects molten metal into a metal mold, resulting in a highly accurate metal part. It's used to create complex components for industries such as automotive, aerospace, and electronics.

What is die casting?

With the rapid development of metal die casting technology, Tesla is the first to use an integrated die casting body, which integrates 70 parts into one die casting process. Many car companies have also followed up, and the die-casting body technology naturally has its unique charm. So, what is the metal die casting process? Today we will make a brief introduction.

What is die casting

Die casting is the use of machine, mold and alloy and other three elements, the pressure, speed and time of the process of unification, it is a modern metal processing technology in the rapid development of a less, no cutting special casting method, is the molten metal filling mold under high pressure and high speed, and the process of crystallization and solidification forming castings under high pressure.

Die casting equipment converts electrical energy from the motor through the motor into hydraulic energy of the pump, thus performing actions (i.e. opening and closing the mold and spraying molten metal into the mold cavity).

The injection part of the die casting process uses the energy of the hydraulic system to push the punch, thereby pushing the molten metal into the mold cavity. Before the molten metal enters the mold cavity, it passes through a flow channel called a runner and a smaller cross-sectional section called a gate. The gate has the effect of accelerating the flow of metal, and it also makes the runner system easily detached from the casting.

Advantages and disadvantages of die casting process

Advantages:

1. It can manufacture metal parts with complex shape, clear outline, thin wall and deep cavity

2. High production efficiency

3. High material utilization, only after a small amount of subsequent processing can get the required product shape.

Disadvantages:

1. There are often pores and oxidizing inclusions in die casting parts.

2. The size of the die casting and the type of alloy are limited.

Main die casting alloy

Die-casting alloy is one of the key elements of die-casting production, when choosing die-casting alloy, it is necessary to fully consider its performance, process performance, application occasions, production conditions and so on.

AL-Si alloy: The crystallization temperature interval is small, the silicon phase in the alloy has a large latent heat of solidification and a large specific heat capacity, and the linear shrinkage coefficient is also relatively small.

AL-Mg alloy: Good mechanical properties at room temperature. The corrosion resistance is strong, the casting performance is relatively poor, and the fluctuation of mechanical properties and wall thickness effect are relatively large.

AL-Zn alloy: High mechanical properties can be obtained after natural failure of die casting parts.

Current application of die casting process

Based on the characteristics of high production efficiency, complex casting and high precision, die casting process is widely used in automobile, tractor, electrical instrument, telecommunication equipment, aerospace, medical equipment and light industry daily hardware industry. The main parts produced by die casting process are engine cylinder body, cylinder cover, gearbox, engine cover, instrument and camera shell and bracket.

Application of chemicals in die casting process

1. Punch oil

During the die casting process, for each injection, the punch must dynamically contact the punch oil once and rub against the chamber once. The flexible and reliable motion of the injection mechanism depends on the smooth movement of the punch and the stability of the clearance between the punch and the sleeve. The performance of the injection system is critical to the production of high-quality die castings (castings must be free of porosity and non-metallic inclusion, while ensuring dimensional accuracy and mechanical properties), control of the metal pressure during and after filling, and the volume and speed of the metal injected into the mold. It can be said that the infallible punch system is the soul of successful die casting. And good lubrication performance is the key to ensure the normal injection system.

2. Release agent

In the die casting process, the mold is constantly heated by high temperature liquid metal, and its temperature continues to rise. Too high mold temperature will cause some defects in die casting, such as sticky mold, bubbling, cracking, hot cracking, etc. At the same time, the mold works in a high temperature environment for a long time, the strength of the mold material decreases, resulting in cracks on the surface of the mold, resulting in a decline in the life of the mold. In order to alleviate or solve the above problems, spraying or coating release agent is often used in the production of workpiece. Release agent is a functional substance between the mold and the finished product. It can form a uniform release film on the surface of the mold, so that the mold can be released, and the product maintains integrity and post-processability.

3. Fire resistant hydraulic oil

Die casting equipment usually works in high temperature environment. Daily leakage or pipe, joint rupture and other unexpected events, so that the traditional mineral based hydraulic oil has a hidden danger of fire, equipment and operators pose a serious threat to life safety. Therefore, flame resistant hydraulic fluid should be selected to ensure the stable operation of the hydraulic system under pressure conditions, open flame and high temperature environment.

If you are interested in die casting process and have demand for die casting products, our company has perfect equipment to provide you with high quality and good price products, please feel free to contact us.