Aluminium Pressure Die Casting

Aluminum High Pressure Die Casting in Innovaw

In order to better provide one-stop service to our customers, Innovaw continues to maintain a high investment in research and development in the field of high pressure die casting.

We have product development engineers and process experts who specialize in high pressure die casting.

We will continue to introduce industry advanced high pressure die casting equipment. We continue to improve the details of our high pressure die casting process in practice, pursuing every ounce of progress.

We continue to study the material properties and the best application of different materials in the field of high pressure die casting.

What Is High Pressure Die Casting (HPDC)?

 The High Pressure Die Casting (HPDC) process is a widely used manufacturing technique for producing aluminum components with high precision and efficiency.

There are two basic types of die casting machines: hot chamber and cold chamber.

Hot chamber die casting

Hot chamber die casting, which has a pool of liquid, semi-liquid metal in a molten state, and its pressure chamber is placed in the liquid metal of an insulated melting crucible, with the ejection parts located at the top of the crucible. This metal fills the mold under pressure. At the beginning of the cycle, the piston of the machine is contracted so that the molten metal can fill the gooseneck area. A pneumatic or hydraulic piston squeezes the metal to fill the mold. Advantages of this system include high cycle speeds (approximately 15 cycles per minute), ease of automation, and ease of melting the metal. Disadvantages include the inability to die cast metals with higher melting points, and likewise aluminum, which will take the iron out of the melting pool. As a result, hot chamber die casting machines are generally used for zinc, tin and lead alloys. Also, hot chamber die casting is difficult to use for die casting large castings, usually this process is die casting small castings.

Cold chamber die casting

When die casting can not be used for hot chamber die casting process of metal can be used cold chamber die casting, including aluminum, magnesium, copper, and zinc alloy with high aluminum content. Cold chamber die casting machine pressure chamber and holding furnace independent, need in a separate crucible first to melt off the metal, die casting a certain amount of molten metal from the holding furnace is taken out of the pouring pressure chamber. By means of hydraulic or mechanical pressure, this metal is injected into the mold. The biggest disadvantage of this process is the long cycle times due to the need to transfer the molten metal into the cold chamber.

2. Advantages of HPDC

The High Pressure Die Casting process offers several advantages:

- High precision and surface finish: The process produces parts with excellent dimensional accuracy and a smooth surface finish, often requiring little additional machining.

- Complex Geometries: HPDC can create complex designs that are difficult to achieve with other manufacturing methods.

- Material Efficiency: The process produces minimal waste because excess material can often be recycled.

- Rapid production: HPDC allows for fast cycle times, making it suitable for high volume production.

3. Applications

Aluminum die casting is particularly well suited for parts requiring good strength-to-weight ratios, corrosion resistance and thermal conductivity. It is the most widely accepted process for producing parts in the automotive, electrical, surgical, consumer, aerospace, medical and electric vehicle industries. In particular, the automotive industry makes extensive use of the high-pressure die casting manufacturing process to create highly complex parts that have economic value. Almost every industry has die casting applications. Especially castings made of special aluminum alloys.

4. The advantages of aluminum die casting parts:

Ease of mass production: Die casting is ideal for mass production. This process saves time when producing large quantities of the same part. This means you can go from prototype to mass production in a matter of weeks!

Dimensional accuracy and stability: Components manufactured through the die casting process have tight tolerances and excellent precision. Durability, heat resistance and excellent surface finish: Die casting gives products a high-quality surface finish at the die casting stage, with surface RA values in the range of 2-100 µm (0.5-2.5 µin). It reduces the need for surface finish machining operations and in some cases can even eliminate it completely.

Excellent machinability: One of the many benefits of using aluminum castings in manufacturing is their excellent machinability.

Thin Wall Thicknesses and Light Weight: Die casting is one of the most efficient ways to manufacture thin, strong products. It allows us to produce products with wall thicknesses of up to 1mm, making them lighter without sacrificing precision and strength, while saving money.

Aluminum die castings are lightweight, corrosion-resistant, thermally and electrically conductive, and extremely durable. Even with thin wall thicknesses or complex shapes, aluminum die castings retain their strength and maintain their dimensional stability at high temperatures. Aluminum die castings are lightweight and have excellent durability and recyclability.

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