Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Die casting is a manufacturing process where molten metal is injected under high pressure into a steel mold (die) to produce precise, complex metal parts. Here’s a concise overview of how it’s made, based on current knowledge:

1.Steps in Die Casting:

a.Mold Preparation:A two-part steel mold (die) is designed with cavities matching the desired part’s shape.The die is cleaned, lubricated, and preheated to ensure smooth operation and prevent thermal shock.

b.Melting and Alloying:Metals like aluminum, zinc, magnesium, or copper alloys are melted in a furnace at high temperatures (e.g., ~650–700°C for aluminum).Alloys are chosen for strength, weight, or corrosion resistance.

c.Injection:Molten metal is transferred (via ladle or automated system) to a shot chamber.A piston injects the metal into the die at high pressure (10–30 MPa) and speed, filling the cavity in milliseconds.

d.Cooling and Solidification:The molten metal cools and solidifies inside the die, typically within seconds, due to the die’s cooling channels (using water or oil).Cooling time depends on part size and material.

e.Ejection:Once solidified, the die opens, and ejector pins push the part out.The part may still be hot and is handled carefully to avoid deformation.

f.Trimming and Finishing:Excess material (flash, sprues, or runners) is trimmed via cutting or pressing.Parts may undergo secondary processes like machining, polishing, or coating (e.g., powder coating, plating) for enhanced aesthetics or functionality.

2.Key Equipment:

Die Casting Machine: Hot-chamber (for low-melting-point metals like zinc) or cold-chamber (for high-melting-point metals like aluminum).

Dies: Precision-engineered, reusable steel molds.

Furnace: For melting and holding molten metal.

Trimming Tools: For removing excess material.

3.Types of Die Casting:

High-Pressure Die Casting: Most common, used for high-volume production of small-to-medium parts.

Low-Pressure Die Casting: For larger parts with less complexity.

Vacuum Die Casting: Reduces air entrapment for higher-quality parts.

4.Advantages:

High precision and repeatability.

Smooth surface finish.

Suitable for complex shapes and thin walls.

Fast production for large volumes.

5.Limitations:

High initial cost for dies and machines.

Limited to non-ferrous metals (e.g., aluminum, zinc).

Not ideal for low-volume production.