Aluminum alloy product design and molding process - die casting
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發布日期:2015-03-06
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1 Die casting is a widely used metal casting processDie casting is a metal casting process characterized by the use of a mold cavity to apply high pressure to the molten metal. Depending on ..........

1 Die casting is a widely used metal casting process

Die casting is a metal casting process characterized by the use of a mold cavity to apply high pressure to the molten metal. Depending on the type of die casting, a cold chamber die casting machine or a hot chamber die casting machine is required. Casting equipment and molds are expensive, so the die casting process is generally only used to mass produce a large number of products. Die casting is particularly suitable for the manufacture of a large number of small and medium-sized castings, so die casting is the most widely used of various casting processes. Compared to other casting techniques, the die-cast surface is flatter and has a higher dimensional consistency.

2 development history of die casting process

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Image source:rangersdiecasting

In 1838, Gee Bruce first produced lead characters by die casting.

In 1839, a piston die casting machine won the first patent for pressure casting. In 1849, the British Spodos patented the hot-press chamber die casting machine. In 1885, O. Morgan Searle invented a typeface die casting machine based on his predecessors. In 1907 Wagner first made a pneumatic piston die casting machine. In 1920, the UK developed a cold-press chamber die-casting machine, which made it possible to produce die-casting parts such as aluminum alloy and magnesium alloy. In 1927, the Czech Joseph Polak designed a vertical cold chamber die casting machine. In 1952, the Soviet Union produced the first vertical cold press chamber die casting machine. China has also produced such a die casting machine in the 1960s. In 1958, the vacuum die casting machine was patented in the United States. In 1966, American General Motors proposed fine, fast and dense die casting. In 1969, American Eleks proposed a non-porous die casting method for oxygen-filled die casting.

3 process
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Image source: learneasy

Hot chamber die casting

Hot chamber die casting, sometimes referred to as gooseneck die casting, is a molten, liquid, semi-liquid metal in a metal pool that fills the mold under pressure.

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Image source: learneasy

Cold chamber die casting

Cold die-casting can be used when die-casting metal that cannot be used in the hot chamber die casting process, including aluminum, magnesium, copper, and zinc alloys with a high aluminum content.

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Image source: learneasy

4 applicable metal materials and applications

Zinc

The most easily die-cast metal is economical when manufacturing small parts, easy to coat, high in compressive strength, high plasticity, and long casting life.

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Image source: roshiq

aluminum

Light weight, complex manufacturing and thin-walled castings have high dimensional stability, high corrosion resistance, good mechanical properties, high thermal conductivity and electrical conductivity, and high strength at high temperatures.

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Source: roshiq.com

magnesium

Easy to machine, high strength to weight ratio, the lightest among the commonly used die-casting metals.

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Image source: buhlergroup

Panasonic Lumix GX7 – Die Cast Magnesium Body

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Image source; photographyreview

copper

High hardness and strong corrosion resistance. The mechanical properties of die-casting metals are the best, anti-wear and strength close to steel.

Die-cast copper rotor

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Image source: kienle-spiess

Die-cast copper strip

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Image source: bronmetal

Lead and tin

High density and high dimensional accuracy for special corrosion protection parts. For reasons of public health, this alloy cannot be used as a food processing and storage facility. Lead-tin-bismuth alloys (sometimes also containing a bit of copper) can be used to make hand-finished lettering and hot stamping in letterpress printing.

Some applications of aluminum alloy die castings and zinc alloy die castings in the automotive sector:

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Image source: ikd-china

5 advantages and disadvantages of die casting

The advantages of die casting include the excellent dimensional accuracy of the casting. The biggest drawback of die casting is the high cost. Casting equipment as well as mold and mold related components are expensive compared to other casting methods. Therefore, it is economical to produce a large number of products when manufacturing die castings. Other disadvantages include: This process is only suitable for metals with higher mobility.

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