Shenzhen Alu Rapid Prototype Precision Co., Ltd.

High-pressure die casting (HPDC) is a highly efficient metal casting process used to produce complex, high-precision parts in large volumes. It involves forcing molten metal under high pressure (typically 1,500–25,000 psi or 10–175 MPa) into a reusable steel mold (called a die), where it rapidly solidifies into a near-net-shape component.

How the HPDC Process Works

The process typically follows these key steps:

1.Die Preparation — The two halves of the steel die are sprayed with lubricant to control temperature and aid part release.

2.Injection — Molten metal is injected at high speed and pressure into the closed die cavity.

3.Solidification — Pressure is maintained until the metal cools and hardens (often in seconds).

4.Ejection — The die opens, and the casting is ejected.

5.Trimming/Shakeout — Excess material (flash or runners) is removed.

There are two main variants:

1.Hot-chamber → Suitable for lower-melting-point metals like zinc and magnesium; the injection system is immersed in molten metal for faster cycles.

2.Cold-chamber → Used for higher-melting-point metals like aluminum; molten metal is ladled into the chamber before injection.

Common Materials

1.Aluminum (lightweight, corrosion-resistant)

2.Zinc (excellent precision and surface finish)

3.Magnesium (lightest structural metal)

Advantages

1.High production rates (fast cycle times)

2.Excellent dimensional accuracy and smooth surfaces (minimal machining needed)

3.Ability to produce thin-walled, intricate geometries

4.Cost-effective for high-volume manufacturing

Disadvantages

1.High initial tooling costs (dies are expensive)

2.Potential for porosity due to trapped air (though mitigated with vacuum systems)

3.Limited to non-ferrous metals