{"id":1691,"date":"2024-12-24T18:33:55","date_gmt":"2024-12-24T10:33:55","guid":{"rendered":"https:\/\/www.hexinmusu.com\/?p=1691"},"modified":"2025-01-08T14:31:48","modified_gmt":"2025-01-08T06:31:48","slug":"about-detail-29","status":"publish","type":"post","link":"https:\/\/www.hexinmusu.com\/en\/about-detail-29.html","title":{"rendered":"Die casting technology: a key manufacturing process for turning visions into reality"},"content":{"rendered":"
In modern manufacturing, the die-casting process is regarded as an important means of manufacturing precision metal parts. It injects molten metal into precision molds at high pressure, enabling the production of complex shaped metal parts, which are widely used in automotive, electronics and other fields, supporting the technological development of several leading industries. This paper will provide an in-depth analysis of the core processes, material selection and applications of the die casting process, and how this process can achieve innovation and excellence in manufacturing.<\/p>\n\n\n\n Die casting is an efficient and precise method of metal casting that utilizes reusable molds to produce complex shaped metal parts. Unlike traditional casting processes, die casting injects molten metal into the mold under high pressure, making it particularly suited to high-volume production and providing high precision, repeatability, and excellent surface finish.<\/p>\n\n\n\n The die casting process was initially used in the printing industry, but its potential for widespread use soon expanded to a number of fields, including the automotive, aerospace and electronics industries. Today, die casting uses primarily lightweight metals such as aluminum, zinc and magnesium to meet the manufacturing needs of a wide range of products, from small, complex components to critical automotive parts. The core advantage of die casting is its ability to create parts with extremely tight tolerances and reduced need for subsequent machining, making it an indispensable technology in modern manufacturing.<\/p>\n\n\n\n The production process of die casting can be divided into several key steps:<\/p>\n\n\n\n Depending on the melting and injection process, the die casting process can be divided into two main types: hot chamber die casting and cold chamber die casting:<\/p>\n\n\n\n As technology continues to evolve, the die casting process has seen a variety of variants and innovations to meet different industrial needs. For example:<\/p>\n\n\n\n The advantages of metal die casting, a manufacturing process widely used in industrial production, have made it an important part of high-volume production. However, it also has some limitations that may affect its use in certain application scenarios. The following is an analysis of the main advantages and disadvantages of die casting and the reasons for them:<\/p>\n\n\n\n The metal materials used in the die casting process are usually non-ferrous alloys such as aluminum, magnesium and zinc. These alloys have different performance characteristics and are suitable for different application requirements. The following table provides a detailed comparison of common die casting alloys, listing their main compositions, melting points, properties, and typical applications.<\/p>\n\n\n\n Die casting is often confused with other manufacturing processes (e.g., injection molding, forging, stamping, etc.), especially for those new to manufacturing. Despite their similarities, each process has its own unique benefits and areas of application. Below is a comparison of die casting with common processes such as injection molding and forging to help understand the differences and application scenarios:<\/p>\n\n\n\n Die casting and injection molding are two popular molding processes that use the principle of injection and are suitable for creating parts with intricate details and excellent surface finishes. However, their applicable materials and processes differ. The following are the main differences between the two:<\/p>\n\n\n\n The main difference between forging and die casting is the way they are molded. Forging involves molding metal in a solid state by applying compressive force, while die casting involves injecting molten metal into a pre-designed mold. The two processes also differ in terms of applicable materials, production speed and part performance:<\/p>\n\n\n\n Stamping is a process of forming metal sheets by means of a press, and is suitable for the mass production of thin-walled parts. Compared to die casting, stamping has different molding materials and processes, especially in terms of the complexity of the applicable parts and productivity:<\/p>\n\n\n\n 3D printing is an additive manufacturing-based process that creates parts by stacking materials layer by layer. 3D printing offers greater flexibility and faster prototyping capabilities than die casting, but differs in production speed and part performance:<\/p>\n\n\n\n Aluminum, zinc, magnesium and other alloys are common die-casting materials, they each have unique properties, suitable for different application scenarios. The following are the characteristics of several common alloys:<\/p>\n\n\n\n Die casting design is not only dependent on material selection, but also needs to consider factors such as part geometry, draft angle, fillet radius, etc., in order to improve part performance, manufacturability and cost-effectiveness. For example, a proper draft angle can effectively prevent parts from sticking to the mold and reduce the risk of damage; a reasonable fillet radius can help evenly distribute stresses and avoid stress concentrations.<\/p>\n\n\n\n Die casting has become an indispensable technology in modern manufacturing due to its high precision and high volume production capabilities. Whether it's automotive parts, electronic housings, or aerospace components, die casting technology provides a solid foundation for innovation and design excellence. As materials and processes continue to advance, die casting will continue to bring more efficient, higher quality solutions to a wide range of industries in the future.<\/p>\n\n\n\n Why are die castings prone to porosity?<\/strong> Why are defects likely to appear on the surface of die castings?<\/strong> What is the problem with shrinkage holes in die castings?<\/strong> Are die castings prone to cracking?<\/strong> What about dimensional instability of die castings?<\/strong> How does mold wear affect die casting quality?<\/strong> Why are die castings prone to deformation?<\/strong> How can cold segregation be reduced?<\/strong> Is post-processing of die castings necessary?<\/strong> In modern manufacturing, the die-casting process is regarded as an important means of manufacturing precision metal parts. It injects molten metal into precision molds at high pressure, enabling the production of complex shaped metal parts, which are widely used in automotive, electronics and other fields, supporting the technological development of several leading industries. This article will provide an in-depth analysis of the core processes, material selection and applications of the die casting process, and how this process can achieve innovation and excellence in manufacturing. What is die casting? Die casting is a highly efficient and precise method of casting metal, utilizing reusable molds to produce complex shaped metal parts. Unlike traditional casting processes, die casting injects molten metal into a mold under high pressure and is particularly suited to high-volume production, providing high precision, repeatability, and excellent surface finishes. Die casting ...<\/p>","protected":false},"author":1,"featured_media":1694,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":[],"categories":[21],"tags":[49,102,98,69],"class_list":["post-1691","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-about-news","tag-die-casting","tag-die-casting-process","tag-die-casting-die","tag-aluminum-alloy-manufacturing-process"],"_links":{"self":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1691","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/comments?post=1691"}],"version-history":[{"count":0,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/posts\/1691\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media\/1694"}],"wp:attachment":[{"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/media?parent=1691"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/categories?post=1691"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.hexinmusu.com\/en\/wp-json\/wp\/v2\/tags?post=1691"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}<\/figure>\n\n\n\n
What is die casting?<\/h2>\n\n\n\n
Die Casting Process<\/h2>\n\n\n\n
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Molds are the foundation of the die casting process, and common types of molds include single cavity molds, multi-cavity molds, and combination molds. Mold design needs to consider the complexity of the part and the scale of production, the mold needs to be cleaned and preheated before use to avoid cracks and thermal defects.<\/li>\n\n\n\n
During the injection process, molten metal is melted and injected into the mold in different systems. In the case of the hot chamber system, the melting takes place inside the casting machine, while the cold chamber system pours the molten metal into the cold chamber where it is injected into the mold by pressure.<\/li>\n\n\n\n
The molten metal is cooled and solidified in a mold to form the final part. The cooling process requires controlled pressure to prevent defects in the part due to shrinkage.<\/li>\n\n\n\n
Once the metal is fully solidified, the mold is opened and the machine ejector pushes the part out.<\/li>\n\n\n\n
To ensure the quality of the part, excess material and burrs need to be removed. If necessary, the accuracy of the part can be further improved by post-processing methods such as grinding.<\/li>\n<\/ol>\n\n\n\nTypes of Die Casting<\/h2>\n\n\n\n
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For low melting point metals such as zinc and certain aluminum alloys. The process uses a pneumatic plunger to inject metal into the mold through a molten metal reservoir attached to the die casting machine. It is efficient and fast, and is suitable for high volume production of small parts, commonly used in the production of consumer electronics.<\/li>\n\n\n\n
Used for high melting point metals such as aluminum and copper alloys. In cold chamber die casting, molten metal is first poured into a cold chamber and then injected into the mold through a plunger. This process is suitable for parts requiring high strength and heat resistance and is widely used in automotive and aerospace applications.<\/li>\n<\/ul>\n\n\n\n<\/figure>\n\n\n\n
Die casting variants and innovations<\/h2>\n\n\n\n
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Comparison of advantages and disadvantages of die casting<\/h2>\n\n\n\n
Advantages of Die Casting<\/h3>\n\n\n\n
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Metal die casting is capable of producing parts with high dimensional accuracy, especially for applications requiring tight tolerances. Accuracy depends on the mold design and manufacturing process, and higher dimensional accuracy can be achieved especially when the molds are manufactured using high-precision CNC machines, such as 5-axis CNC machines. In addition, the use of process variants such as low pressure die casting (LPDC) and gravity die casting helps to fill the molds accurately, thus increasing the accuracy of the parts.<\/li>\n\n\n\n
Die casting is capable of producing parts with complex geometries, including castings, thin walls, and other designs. This characteristic has enabled die casting to produce parts with complex structures and a wide range of functions in fields such as aerospace, automotive and consumer electronics. In this way, designers can integrate more functionality into a single part, reducing the need for subsequent assembly.<\/li>\n\n\n\n
Die casting is a high-volume production process suitable for making large quantities of parts. In high-pressure casting, production is faster due to the high pressure used, which reduces the production cost per part. Especially in the case of using a combination of molds, multiple parts can be manufactured at the same time, increasing productivity and cost-effectiveness per part.<\/li>\n\n\n\n
Due to the high pressure injection of metal during the die casting process, cast metal parts usually have a smooth surface finish, especially in low-pressure casting, gravity casting and other processes. This high quality surface finish not only improves the appearance quality of the part, but also reduces the amount of effort required for subsequent surface treatment.<\/li>\n\n\n\n
Die casting molds are usually made of high quality steel with excellent resistance to high temperatures and pressures. These tough steels enable the molds to withstand prolonged use and have a long service life, reducing the frequency of mold replacement and maintenance costs for long-term production.<\/li>\n<\/ol>\n\n\n\nDisadvantages of die casting<\/h3>\n\n\n\n
\n
The die casting process is mainly applied to non-ferrous metals such as aluminum, zinc and magnesium. These metals have moderate melting points and are easy to inject into molds under high pressure. However, for ferrous metals with higher melting points, such as steel and iron, die casting is not suitable. Metals such as steel and iron require special equipment and more complex processes to cast, which makes the application of die casting somewhat limited.<\/li>\n\n\n\n
Die casting molds are expensive to manufacture, especially when CNC machining is used, and the process of making the molds is complex and costly. Especially when manufacturing complex parts, the use of high-quality steel molds will further push up the cost. While the die casting process is suitable for high volume production, the cost of its molds can be a limiting factor for small batches or complex parts.<\/li>\n\n\n\n
Die casting parts in the production process may appear porosity, shrinkage, porosity and other defects, especially in high-pressure casting, these defects are more common. For example, air retention during the casting process may lead to the creation of pores on the surface of the part, and these pores may form air bubbles during heat treatment, affecting the quality of the part. Additional surface finishing steps may be required to address these defects, increasing production costs.<\/li>\n\n\n\n
Although die casting is suitable for mass production, its initial investment is high, especially the fixed costs of mold manufacturing and equipment setup. As a result, the die casting process is usually not suitable for small-scale production or one-off part production. For small-scale production, other processes (such as injection molding or CNC machining) may be more appropriate and can reduce costs and production lead times.<\/li>\n<\/ol>\n\n\n\nHershey's Metal Materials in Die Casting<\/h2>\n\n\n\n
alloys<\/strong><\/th> Common subtypes<\/strong><\/th> base<\/strong><\/th> Melting point (\u00b0C)<\/strong><\/th> Main characteristics<\/strong><\/th> typical application<\/strong><\/th><\/tr><\/thead> aluminum<\/strong><\/td> a380, a360, a390, a413, adc12<\/td> Aluminum (Al), Copper (Cu), Silicon (Si), Magnesium (Mg)<\/td> 577 - 660<\/td> Light weight, corrosion resistant, high strength, good workability and cost effective.<\/td> Automotive (engine components, wheels, chassis), aerospace (structural components, housings), electronics (housings, bodies)<\/td><\/tr> magnesium alloy<\/strong><\/td> az91d, am60b, as41b<\/td> Magnesium (Mg), Aluminum (Al), Zinc (Zn)<\/td> 632 - 650<\/td> Extremely lightweight, good castability for weight-sensitive applications, excellent castability.<\/td> Aerospace (body structure, interior parts), automotive (lightweight components), electronics (handheld devices, cell phone housings)<\/td><\/tr> zinc alloy<\/strong><\/td> Zinc alloy #2, #3, #5, #7, ZA8, ZA27<\/td> Zinc (Zn), Aluminum (Al), Copper (Cu), Magnesium (Mg)<\/td> 381 - 419<\/td> Excellent castability, low melting point, suitable for complex designs and cost effective.<\/td> Electronics (connectors, housings), hardware (locks, buttons), toys and automotive parts (decorative parts, gears)<\/td><\/tr> copper alloy<\/strong><\/td> Brass (e.g. C85700), bronze (e.g. C93200)<\/td> Copper (Cu), Zinc (Zn) (Brass); Copper (Cu), Tin (Sn) (Bronze)<\/td> 900 - 1083<\/td> High strength, excellent conductivity and corrosion resistance, durable.<\/td> Piping (corrosion-resistant water pipes, gas pipes), electrical connectors (terminals, electrical contacts), marine components (corrosion-resistant components), bearings<\/td><\/tr> tin alloy<\/strong><\/td> -<\/td> Tin (Sn) (90%), Copper (Cu) (2.5%), Lead (Pb) (7.5%), Antimony (Sb)<\/td> 170 - 230<\/td> Low melting point, good fluidity, corrosion resistance, easy casting.<\/td> Decorative items (jewelry, handicrafts), figurines, souvenirs<\/td><\/tr> lead alloy<\/strong><\/td> -<\/td> Lead (Pb), Tin (Sn)<\/td> 183 - 327<\/td> Low melting point, soft, good corrosion resistance, suitable for radiation shielding.<\/td> Radiation shielding (medical equipment, nuclear facilities), batteries (gradually being replaced)<\/td><\/tr> tin-based alloy<\/strong><\/td> -<\/td> Tin (Sn), Copper (Cu), Antimony (Sb)<\/td> 232<\/td> Low melting point, good casting properties, good corrosion resistance.<\/td> Electronic components (soldering materials, electronic parts), jewelry, special applications (small parts, fine jewelry)<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n Comparison of die casting with other manufacturing processes<\/h2>\n\n\n\n
Difference between die casting and injection molding<\/h3>\n\n\n\n
discrepancy<\/th> Die casting<\/th> injection molding<\/th><\/tr><\/thead> workflows<\/strong><\/td> Injection of molten metal under pressure into pre-designed steel molds<\/td> Injection of molten plastic under pressure into pre-designed steel or aluminum molds<\/td><\/tr> makings<\/strong><\/td> Non-ferrous metal alloys (e.g. aluminum, zinc, magnesium)<\/td> Thermoplastics or thermosets<\/td><\/tr> Mold Materials<\/strong><\/td> steel (chemistry)<\/td> Steel or Aluminum<\/td><\/tr> cooldown<\/strong><\/td> Longer cooldown time<\/td> Shorter cooldown<\/td><\/tr> production speed<\/strong><\/td> relatively slow<\/td> relatively soon<\/td><\/tr> processing cost<\/strong><\/td> Higher mold costs (using steel molds)<\/td> Lower tooling costs (using aluminum tooling)<\/td><\/tr> component cost<\/strong><\/td> Higher (due to longer production time)<\/td> Lower (faster production time)<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n Difference between die casting and forging<\/h3>\n\n\n\n
discrepancy<\/th> forge (metal)<\/th> Die casting<\/th><\/tr><\/thead> workflows<\/strong><\/td> Forming of heated metal by applying compressive force<\/td> Injection of molten metal into a mold under pressure<\/td><\/tr> makings<\/strong><\/td> For ferrous and non-ferrous metals, such as steel, aluminum<\/td> For non-ferrous metals such as aluminum, zinc, magnesium<\/td><\/tr> Molding materials<\/strong><\/td> Does not require a mold, but uses a mold to optimize the shape<\/td> Must use molds<\/td><\/tr> production speed<\/strong><\/td> slower<\/td> relatively soon<\/td><\/tr> tolerance control<\/strong><\/td> Medium tolerance<\/td> High precision tolerance control<\/td><\/tr> Final Part Properties<\/strong><\/td> Improvement of mechanical properties<\/td> Mechanical properties depend on the casting material<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n Difference between die casting and stamping<\/h3>\n\n\n\n
discrepancy<\/th> Die casting<\/th> punch<\/th><\/tr><\/thead> workflows<\/strong><\/td> Injecting molten metal into a mold to form a shape<\/td> Forming parts by stamping metal sheets using a die.<\/td><\/tr> makings<\/strong><\/td> Mainly non-ferrous metal alloys (e.g. aluminum, zinc)<\/td> Suitable for various metal sheets (e.g. steel, aluminum)<\/td><\/tr> Mold Materials<\/strong><\/td> steel (chemistry)<\/td> steel (chemistry)<\/td><\/tr> Part Shape<\/strong><\/td> For complex shaped parts<\/td> For thin-walled parts and simple shapes<\/td><\/tr> production speed<\/strong><\/td> slower<\/td> relatively soon<\/td><\/tr> accurate<\/strong><\/td> highly accurate<\/td> Lower precision<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n Difference between die casting and 3D printing<\/h3>\n\n\n\n
discrepancy<\/th> Die casting<\/th> 3D printing<\/th><\/tr><\/thead> workflows<\/strong><\/td> Injecting molten metal into a mold to form a shape<\/td> Layer-by-layer printing of materials based on digital models<\/td><\/tr> makings<\/strong><\/td> Non-ferrous metal alloys (e.g. aluminum, zinc)<\/td> Thermoplastics, metal powders, etc.<\/td><\/tr> Mold Materials<\/strong><\/td> steel (chemistry)<\/td> No molds required<\/td><\/tr> production speed<\/strong><\/td> slower<\/td> relatively soon<\/td><\/tr> accurate<\/strong><\/td> highly accurate<\/td> Moderate precision<\/td><\/tr> appliance<\/strong><\/td> Mass production of complex parts<\/td> Rapid prototyping, low volume production<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n Common die casting materials and selection<\/h2>\n\n\n\n
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Design and Manufacturing Optimization<\/h2>\n\n\n\n
reach a verdict<\/h2>\n\n\n\n
Die casting common problems and coping strategies<\/h2>\n\n\n\n
Pockets are usually caused by the metal not venting completely during the injection process, or by defective mold design (e.g., poor venting system). Strategies include optimizing the mold venting design, adjusting the injection speed and pressure, and using a more efficient venting system.<\/p>\n\n\n\n
Surface imperfections such as bubbles, creases and scratches are mostly caused by uneven mold surfaces or uneven metal flow. To avoid such problems, the surface finish of the mold should be checked regularly to ensure that the injection temperature and flow rate are stable.<\/p>\n\n\n\n
Shrinkage hole is due to the casting cooling metal shrinkage failed to replenish the filler, often appear in large or complex shape die casting. Shrinkage holes can be effectively avoided by optimizing the mold design, improving the efficiency of the pouring system and adjusting the cooling rate.<\/p>\n\n\n\n
Cracking usually occurs when the metal flows unevenly or cools too quickly, and can be caused by excessive injection pressure or poor mold design. Cracking can be minimized by controlling injection speed, temperature and pressure, and by using high-strength materials.<\/p>\n\n\n\n
Dimensional instability may be due to mold wear, unstable injection pressure or improper temperature control. Regular overhaul and maintenance of the mold to maintain stable injection conditions, as well as fine tuning of the temperature control system, can effectively solve the problem of dimensional instability.<\/p>\n\n\n\n
Wear of molds can lead to loss of product precision and even affect the appearance and performance of castings. In order to cope with the problem of die wear, the dies should be inspected and replaced regularly, wear-resistant materials should be used, and the design and process of the dies should be optimized.<\/p>\n\n\n\n
Deformation is usually due to uneven cooling or poor mold design, especially when the casting is large or complex. The risk of distortion can be reduced by adjusting the cooling system and optimizing the mold design.<\/p>\n\n\n\n
Cold segregation is a delamination defect formed due to the failure of the metal to fully fuse when injected into the mold. To prevent cold segregation, it is necessary to optimize the injection speed and temperature to ensure smooth metal flow, and reasonably design the pouring system and runner.<\/p>\n\n\n\n
The post-processing requirements for die castings depend on the design requirements and surface quality criteria of the part. Some parts require additional machining such as grinding, drilling or deburring to meet tight tolerances and surface finishes.<\/p>","protected":false},"excerpt":{"rendered":"