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You are here: Home » Technology » Die Casting » High Pressure Casting
Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from non-ferrous metals, specifically aluminium,zinc,copper, magnesium and tin based alloy.The die casting method is especially suited for applications where a large quantity of small to medium sized parts are needed with good detail, a fine surface quality and dimensional consistency.
This level of versatility has placed die castings among the highest volume products made in the metalworking industry.
 
Die-casting Advantage
  • Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and 0.02 mm for each additional centimeter (0.002 in. for each additional inch).
  • Smooth cast surfaces (1--2.5 m (40--100 in.)
  • Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm (0.030 in.).
  • Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces).
  • Reduces or eliminates secondary machining operations.
  • Rapid production rates.
  • Casting tensile strength as high as 415 MPa (60 ksi).

Die casting materials
The main die casting alloys are: aluminium, zinc, magnesium, and copper Specific dies casting alloys include: aluminium, Zamak,AA 380, AA 384, AA 386, AA 390, and AZ91D magnesium. The following is a summary of the advantages of each alloy:
  • Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.
  • Zinc: the easiest alloy to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
  • Magnesium: the easiest alloy to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.
  • Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.
Maximum weight limits for aluminium, brass, magnesium, and zinc castings are approximately 70 pounds (32 kg), 10 lb (5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively
The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below

Metal
Minimum section
Minimum draft
Aluminium alloys
0.89 mm (0.035 in.)
1:100 (0.6)
Brass and bronze
1.27 mm (0.050 in.)
1:80 (0.7)
Magnesium alloys
1.27 mm (0.050 in.)
1:100 (0.6)
Zinc alloys
0.63 mm (0.025 in.)
1:200 (0.3)

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