Die casting is frequently referred to as the fastest route between raw material and finished product.

Because of the differences in the melting temperatures of various die casting alloys, two methods of inserting the molten metal into the die cavities are used. These are referred to as hot chamber and cold chamber machines.

Hot chamber

Hot chamber or plunger machines are used mainly for zinc alloys. With modern technology, this process is increasingly being used for magnesium. The hot chamber process is a preferred die casting method due to its high rate of productivity. However, it cannot be used for some high melting point alloys or for those alloys which attack the steel working parts of the machine.

Operating sequence for the hot chamber die casting process:

1. Die is closed and gooseneck cylinder is filled with molten metal.

2. Plunger pushes molten metal through gooseneck passage and nozzle and into the die cavity. Metal is held under pressure until it solidifies.

3. Die opens and cores, if any, retract. Casting stays in ejector die. Plunger returns, pulling molten metal back through nozzle and gooseneck.

4. Ejector pins push casting out of ejector die. As plunger uncovers inlet hole, molten metal refills gooseneck cylinder

Cold chamber

Cold chamber machines minimize contact between the alloy to be cast and steel machine parts which allows the processing of high melting temperature alloys. Its primary use is for aluminum, brass, and larger magnesium die castings.

Operating sequence for the cold chamber die casting process:

1. Die is closed and molten metal is ladled into the cold chamber cylinder.

2. Plunger pushes molten metal into die cavity. the metal is held under high pressure until it solidifies.

3. Die opens and plunger follows to push the solidified slug from the cylinder. Cores, if any, retract.

4. Ejector pins push casting off ejector die and plunger returns to original position.Die Casting,Pressure Die Casting,Aluminum Die Casting,Alloy Die Casting,Zinc Die Casting,Die Casting Machine Parts,Investment Casting,Aluminum Investment Casting,Carbon Steel Casting,Alloy Steel Casting,Stainless steel casting,Sand Casting,Green Sand Casting,Resin Sand Casting,Iron Sand Casting,Aluminum Casting,Aluminum Casting Alloys,Aluminum Casting Die Process,Aluminum high pressure die casting,Aluminum Pressure Die Casting,Aluminum Gravity Casting,Aluminum Sand Casting,Aluminum Precision Casting,Iron Casting,Ductile Iron Casting,Grey Iron Casting

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At our factory, quality control is an active, function of manufacturing. Quality assurance starts the minute raw materials come in the door and continues through every stage of the casting process. We achieve part-to-part consistency, so the last casting is the same high quality as the first. We work to ISO 9001:2000,a standard of excellence that is recognized around the world.To supply qualified castings with reasonable price is our permanent principle. Dear customers, if you have any interesting to our factory, pls feel free to contact with us by email or fax..Hydraulic Valves-hydraulic Proportional Valves-Hydraulic Flow Control Valve-Hydraulic Control Valve-Hydraulic Pressure Control Valve

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China Ningbo Yinzhou Renyi Casting Machinery Factorty is one of China professionally manufacturer and dedicated supplier of various castings including machining parts, metal machinings, investment casting, sand casting and aluminum die casting one. For investment casting, we adopt the method of soluble glass, complex shell, silicasol to make precision casting parts. And for sand casting, we adopt resin sand process to make grey iron and ductile castings. As for die casting, mostly we make the aluminum or alloy aluminum casting parts. If you have any interesting to our factory, pls feel free to contact with us by email or fax. We can accept the files with the form of Pdf, Jpg, CAD, IGS, STP, Pro-E as well as SOLIDWORKS via email. We sincerely wish we will be your reliable casting, machining parts, metal machinings supplier at the base of mutual benefit.

Die casting machine between 250kN to 1000kN. Aluminum casting cast from several grams to kilograms. Supply finish machining process when customer require.

Aluminum casting with sandblast	Die-casting machine & Alu.liquid container
Die-casting machine03	Die-casting shop
Die-casting machine	Die-casting machine 400T

Die-casting is similar to Permanent mold castings except that the metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) psi . This results in a more uniform part, generally good surface finish and good dimensional accuracy, as good as 0.2 % of casting dimension. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.

Die-casting can be done using a cold chamber or   hot chamber process

1.In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures.

2.In a hot chamber process the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures.

Die casting molds (called dies in the industry) tend to be expensive as they are made from hardened steel-also the cycle time for building these tend to be long. Also the stronger and harder metals such as iron and steel cannot be die-cast

Common Alloys in Die Casting

Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. On the other hand, pure Aluminum die casting is rarely cast due to high shrinkage, and susceptibility to hot cracking. It is alloyed with Silicon, which increases melt fluidity, reduces machinability. Copper is another alloying element, which increases hardness, reduces ductility, and reduces corrosion resistance.

Aluminum is cast at a temperature of 650 ºC (1200 ºF). It is alloyed with Silicon 9% and Copper about 3.5% to form the Aluminum Association 380 alloy (UNS A03800). Silicon increases the melt fluidity, reduces machinability, Copper increases hardness and reduces the ductility. By greatly reducing the amount of Copper (less than 0.6%) the chemical resistance is improved; thus, AA 360 (UNS A03600) is formulated for use in marine environments. A high silicon alloy is used in automotive engines for cylinder castings, AA 390 (UNS A03900) with 17% Silicon for high wear resistance. Common aluminum alloys for die casting are summarized as follows:

Zinc can be made to close tolerances and with thinner walls than Aluminum, due to its high melt fluidity. Zinc is alloyed with Aluminum (4%), which adds strength and hardness. The casting is done at a fairly low temperature of 425 ºC (800 ºF) so the part does not have to cool much before it can be ejected from the die. This, in combination with the fact that Zinc can be run using a hot chamber process allows for a fast fill, fast cooling (and ejection) and a short cycle time. Zinc alloys are used in making precision parts such as sprockets, gears, and connector housings.

Copper alloys are used in plumbing, electrical and marine applications where corrosion and wear resistance is important.

Minimum wall thicknesses and minimum draft angles for die casting are :

Die-castings are typically limited from 20 kg (55 lb) max. for Magnesium, to 35 kg (77 lb) max. for Zinc. Large castings tend to have greater porosity problems, due to entrapped air, and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. The porosity problem can be somewhat overcome by vacuum die casting

From a design point of view, it is best to design parts with uniform wall thicknesses and cores of simple shapes. Heavy sections cause cooling problems, trapped gases causing porosity. All corners should be radiused generously to avoid stress concentration. Draft allowance should be provided to all for releasing the parts-these are typically 0.25º to 0.75º per side depending on the material.

From:http://www.china-die-casting.com/Die_Casting_Technical_Introduction.htm

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NINGBO RENYI CASTING MACHINERY MANUFACTURER is one of China professionally manufacturer and dedicated supplier of various castings including investment casting, sand casting and aluminum die casting one.For investment casting, we adopt the method of soluble glass, complex shell, silicasol to make precision casting parts. And for sand casting, we adopt resin sand process to make grey iron and ductile castings. As for die casting, mostly we make the aluminum or alloy aluminum casting parts.

We can produce castings with kinds of material, such as carbon steel and alloy steel, stainless steel , grey iron, ductile iron, aluminum, brass as well as bronze.Besides, it is also available for us to supply a series of finish steps for the rough casting and metal parts, such as finish machining, welding, heat treating,caseharden, plating, anodizing ,painting etc. Moreover, thanks to our many qualified suppliers for the rubber, plastic injectiong molding,spring, punching,stamping prouducts, that enable us to provide our customers the complete set projects while assemling the correlative products if customers request.

At our factory, quality control is an active, function of manufacturing. Quality assurance starts the minute raw materials come in the door and continues through every stage of the casting process. We achieve part-to-part consistency, so the last casting is the same high quality as the first. We work to ISO 9001:2000,a standard of excellence that is recognized around the world.To supply qualified castings with reasonable price is our permanent principle. Dear customers, if you have any interesting to our factory, pls feel free to contact with us by email or fax. We can accept the files with the form of Pdf, Jpg, CAD, IGS, STP,Pro-E as well as SOLIDWORKS via email. As soon as we receive your inquiry, we will pay much attention to it, and our experienced engineers will make a quick cost estimate to your inquiry, then will quote our competitive price to you at the earliest time. 

We sincerely wish we will be your reliable casting supplier at the base of mutual benefit.

Renyi Casting Guarantee as follows:

1. 100% quality manufacturing

2. All facilities are quality certified.

3. We guarantee that our products meet your supplied specifications

4. Extremely competitive pricing

5. Delivery to your port or front door

7. 6-10 week lead times

8. We handle all paperwork

9. Partial container orders

10. Unique tooling options

11. Full range of packaging options from bulk to retail ready Complete testing services available

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