Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Die casting is a manufacturing process used to produce complex, high-precision metal parts by forcing molten metal into a mold cavity under high pressure. 

1.Steps in the Die Casting Process:

a.Mold Preparation:A steel mold, called a die, is designed with the exact shape of the desired part. The die consists of two halves: a fixed (stationary) half and a movable (ejector) half.The die is cleaned, lubricated, and preheated to ensure smooth operation and prevent thermal shock.

b.Melting and Injection:Metal (commonly aluminum, zinc, magnesium, or copper alloys) is melted in a furnace until it reaches a liquid state.The molten metal is injected into the die cavity under high pressure (typically 1,000 to 30,000 psi) using a hydraulic or mechanical press. This ensures the metal fills the mold's intricate details.

c.Cooling and Solidification:The molten metal cools and solidifies rapidly within the die, taking the shape of the mold. Cooling time depends on the part’s size, thickness, and material but is generally quick due to the metal die’s heat conductivity.

d.Ejection:Once solidified, the die opens, and the cast part is ejected using ejector pins built into the mold.

The part may have slight flash (excess material) that is trimmed off.

e.Finishing:Post-processing steps like trimming, deburring, machining, or surface treatments (e.g., polishing, anodizing, or powder coating) are applied to achieve the desired finish and tolerances.

Quality checks ensure the part meets specifications for dimensions, strength, and surface quality.

2.Types of Die Casting:

a.Hot Chamber Die Casting: Used for metals with low melting points (e.g., zinc, magnesium). The injection system is submerged in molten metal, allowing faster cycles.

b.Cold Chamber Die Casting: Used for high-melting-point metals (e.g., aluminum, copper). Molten metal is ladled into the injection system, which is separate from the furnace, to avoid damage from high temperatures.

3.Advantages:High precision and excellent surface finish.

Suitable for complex geometries and thin walls.

High production rates and cost-effective for large volumes.

Consistent quality and dimensional accuracy.

4.Limitations:High initial tooling costs for die creation.

Limited to metals with suitable melting points and fluidity.

Not ideal for very small production runs due to setup costs.