Learn About Low Pressure Die Casting

What Is Low Pressure Die Casting?

Low-pressure die casting is a method of production that to fill molds with molten metal such as aluminum low pressure casting and magnesium uses pressure rather than gravity. In this process, below the cast the holding furnace is located and through a riser tube and into the cavity the liquid metal is forced upwards.

To fill the mold and hold the metal in place within the die until it solidifies the pressure is applied constantly, sometimes in increasing increments. The pressure is released once the cast has solidified and any residual liquid in the tube or cavity flows back into the holding furnace for recycling. The cast is simply removed when it is cooled.

Benefts of Low-Pressure Die Casting

This method allows you to have precise control of the filling process. If you inject the molten metal in this way then it reduces oxide formation and reduces porosity, and make sure that it is superior consistent from top to bottom.

More complex geometries can be achieved with the use of sand cores within the molds where as the above method is greatly suited to simpler, symmetrical forms. With the benefit of uncomplicated machinery and technology, the low pressure die casting process by aluminum low pressure casting manufacturer lends itself well to automation.

The Auto Industry and Beyond

From decades the automotive industry has relied upon low-pressure die casting to create strong, high-quality aluminum casts. However, its use was primarily limited to the luxury class of the automotive market, due to its relatively slow casting process where lower quantities and higher costs are expected. Now, as ways have been successfully made to make this method more cost-effective, the automotive industry has decreased the time of the casting cycle by 50% and resulted in making low-pressure casting a far more economical choice than it once was.

Although for automotive components such as engine blocks, wheels, and suspension parts low-pressure casting by aluminum low pressure casting machine is an exceptional choice whereas non-automotive industries such as electronics, machine-building, and pipe assemblies take advantage from its exceptional metallurgic quality, lower machining costs and high volume yield. For all of these industries cast aluminum’s superior electrical and thermal conductivity make it a very desirable choice. Follow us on: Facebook

Factors Responsible for Designing a Die Casting Mold

Die casting is a technique that is used for mass-producing metal products and components, and in the process die casting mold design is one of the most important steps because the final product is directly affected by the shape and attributes of the mold at zinc die casting mould company.

 

Importance of Die Casting Mold Design

Mold design affects the uniformity of a product, configuration, shape and quality created through the die casting procedure. If not specified properly it can result in tool or material corrosion, as well as inferior product quality, while efficiency and production time can be improved by an effective design.

Factors that Contribute In Quality Die Casting Mold Design

While deciding on the appropriate specifications for a project there are a number of mold design factors to consider. Three major of these factors include:

Fillets

To smooth an angled surface a fillet is a concave junction that is used. The casting process gets hindered by the sharp corners, so to create rounded edges many molds have fillets and reduce the risk of production errors. With the exception of the parting line, fillets from zinc die casting mould manufacturer can be added nearly anywhere on a mold.

Parting Line

Different sections of the mold together are connected by the parting line, or parting surface. From work strain if the parting line is imprecisely positioned or becomes deformed, through the gap between the mold pieces material may get seep, leading to non-uniform molding and excessive seaming.

Draft  

Draft is the degree to which a core of a zinc die casting mould china can be tapered. To smoothly eject the casting from the die a precise draft is required, but features such as depth of the mold, the type of molten alloy used, and shape of the wall, can affect the process as the draft is not constant and varies according to the angle of the wall. In general, due to the risk of shrinkage untapped holes require tapering. Similarly, inner walls require more drafting than outer walls as they can also shrink. Follow us on Facebook

All You Need To Know about Die Casting Tools and Increased Mold Life

High-pressure die-casting is a technique in which into multi piece reusable molds, liquid metal is pressed over short cycle times.

The mold affects the properties of a die cast part from zamak die casting tooling manufacturer and determines its contours. The weight will not get affected by the action of the filing. Hence, as a result of high-speed fluid flows, the casting processes take place and heat and pressure energy is produced at the end.

For the mass production of, parts made from aluminum, magnesium, and their alloys die casting acts as a forming process .In die casting machines the casting process occurs which are then divided in hot chamber and cold chamber die casting machines.

Accordingly, under special conditions using this die-casting method high-precision and thin-walled castings of high quality and with sharp corners and edges are produced.

Maximum of the nonferrous alloys processed by die-casting consist of zinc, aluminum and magnesium.

While injecting aluminum into a mold, the die-casting done with zamak die casting tooling china is under high thermal and mechanical stresses.

In addition to steel, super alloys are another class of materials that can be used for die-casting molds, which are complex materials that at room temperature and at high temperatures can retain some of their mechanical and physical properties. In aluminum die-casting dies the major issue with super alloys is thermal fatigue, which is a primary reason for failure.

Thermal stresses arise due to change in temperature, which over time in the structure of the mold material may cause damage. This type of damage, which on outer surface appears as tiny cracks, is due to temperature changes. Deep cracks grow gradually and create cracks as gaps. In the lifetime of the die-casting mold the damage caused due to cracks plays a critical role. 

Therefore, in the mold the material that is selected by zamak die casting tooling services for use should have high temperature stability that too without impulsive failure. From heat checking mold materials of aluminum die-casting require resistance and high resistance to soldering and to erosion in a molten aluminum flow of high velocity. Follow on Twitter