Die casting part services aluminum alloy zinc alloy magnesium alloy from Shenzhen China

Die casting is a metal casting process characterized by applying high pressure to molten metal using a mold cavity. Molds are typically machined from stronger alloys, a process somewhat similar to injection molding. Most die-cast castings are iron-free, such as zinc, copper, aluminum, magnesium, lead, tin and lead-tin alloys and their alloys.

Casting equipment and molds are expensive, so the die-casting process is generally only used to manufacture large quantities of products. It is relatively easy to manufacture die-cast parts, which generally requires only four main steps and the individual cost increment is very low. Die casting is particularly suitable for manufacturing a large number of small and medium-sized castings, so die casting is the most widely used among various casting processes. Compared with other casting technologies, die casting has a flatter surface and higher dimensional consistency.

Metals used for die casting mainly include aluminum alloys, magnesium alloys, and zinc alloys.

Zinc alloy: The easiest metal to die-cast, economical to manufacture small parts, easy to coat, high compressive strength, plasticity, long casting life.

Aluminum alloy: light weight, high dimensional stability when manufacturing complex and thin-walled castings, strong corrosion resistance, good mechanical properties, high thermal and electrical conductivity, and high strength at high temperatures.

Magnesium alloy: easy to machine, has a high strength-to-weight ratio, and is the lightest among commonly used die-cast metals.

Advantages of die casting include excellent dimensional accuracy of the castings. Usually this depends on the casting material, typical values are 0.1 mm for the first 2.5 cm of size, increasing by 0.002 mm for each additional 1 cm. Compared with other casting processes, its casting surface is smooth and the fillet radius is approximately 1-2.5 microns. Compared to sandbox or permanent mold casting methods, castings with wall thicknesses of approximately 0.75 mm can be produced. Some other advantages include its ability to reduce or avoid secondary machining, fast production speeds, casting tensile strengths up to 415 MPa, and the ability to cast highly fluid metals.

The biggest disadvantage of die casting is its high cost. Casting equipment as well as molds and mold-related components are expensive compared to other casting methods. Therefore, it is more economical to produce large quantities of products when manufacturing die castings. Other disadvantages include: this process is only suitable for relatively fluid metals, and the casting mass must be between 30 grams and 10 kilograms. In normal die casting, the last batch of castings will always have holes. Therefore, no heat treatment or welding can be performed, because the gas in the gap will expand under the action of heat, causing internal micro-defects and surface peeling.