Die Casting

2024-07-19  By Cherry  

Die casting is an efficient metal-forming process that is widely used in the manufacture of various metal parts.

Overview of Die Casting Process

Die casting is a forming process in which molten metal is injected into the mold cavity under high pressure. This process is suitable for 

manufacturing metal parts with complex shapes, high precision, and high quality.

The die casting process is mainly divided into hot chamber die casting and cold chamber die casting.

1. Hot Chamber Die Casting

Hot chamber die casting is suitable for low melting point metals such as zinc and magnesium.

In this process, the pressure chamber of the die casting machine is directly immersed in the molten metal, and the metal is injected into the mold

through a plunger.

2. Cold Chamber Die Casting

Cold chamber die casting is suitable for high melting point metals such as aluminum and copper.

After the metal is melted in an external furnace, it is injected into the pressure chamber through a conveying system and then injected into the mold 

under high pressure.

Common die-casting materials

There are many types of die-casting materials, including aluminum alloys, zinc alloys, magnesium alloys, etc.

1. Aluminum alloy

Aluminum alloy is one of the most commonly used materials in die-casting, with advantages such as lightweight, high strength and corrosion 

resistance. Aluminum alloys are widely used in automobiles, electronics, aerospace, and other fields.

2. Zinc alloy

Zinc alloy is a low-melting-point metal with excellent casting properties and mechanical properties. Zinc alloy die-castings have the 

characteristics of high precision, good surface finish, and corrosion resistance. Common zinc alloys include ZAMAK 3, whose chemical composition

is zinc, aluminum, copper, and magnesium.

3. Magnesium alloy

Magnesium alloy is the lightest structural metal material with good specific strength and shock absorption performance.

Magnesium alloy die-castings are mainly used in automobiles, electronic products, and other fields that need to reduce weight.

Die-casting application examples

1. Automobile industry

Die-casting is widely used in the automotive industry, such as manufacturing engine blocks, gearbox housings, suspension systems, etc. 

Aluminum alloy die castings are an ideal choice for automobile weight reduction due to their lightweight and high strength.

2. Electronic products

The housing and internal parts of electronic products are often manufactured using die casting technology, with zinc alloy and magnesium 

alloy as the main material. Die castings have high precision, good thermal conductivity, and the ability to shield against electromagnetic 

interference.

3. Aerospace

The aerospace field has extremely high requirements for material performance, and aluminum alloy and magnesium alloy die castings are widely 

used in aircraft structural parts and engine parts.

Die casting surface treatment

After the die casting is manufactured, it is often necessary to perform surface treatment to improve its performance and aesthetics. Common surface 

treatment methods include chromate treatment, chrome plating, polishing, etc.

1. Chromate treatment

Chromate treatment is a chemical treatment method that improves the corrosion resistance and surface hardness of die castings by forming a dense chromate 

film on the metal surface.

2. Chrome plating

Chrome plating is to plate a layer of chrome on the surface of the die casting to enhance its wear resistance, corrosion resistance, and glossiness.

Chrome-plated die castings are widely used in automotive parts, home appliance housings, and other fields.

3. Polishing

Polishing is to remove burrs and unevenness on the surface of die castings by mechanical methods to make the surface smoother. The polished die castings

have a better appearance and touch.

Aluminum castings or called casting aluminum

Aluminum castings are aluminum alloy parts manufactured by casting process, which have the advantages of lightweight, high strength, and corrosion 

resistance.

Casting aluminum is widely used in automobiles, aerospace, electronics, and other fields.

The special die casting process

In addition to the traditional die casting process, investment casting and slider casting are also common casting methods.

1. Investment casting

Investment casting is a precision casting process that uses a fusible material (such as wax) to make a mold, which is then immersed in a refractory 

material to form a shell.

After the mold is melted, the metal is poured into the mold shell, and high-precision castings are obtained after cooling.

2. Slide casting

Slide casting is a casting process that achieves complex shapes by moving the slider inside the mold. This method can manufacture castings with 

complex cavities and multi-layer structures, and is widely used in automotive engine parts and other fields.

Heads up display

Heads up display (HUD) is a display device that projects information in front of the driver's line of sight and is commonly used in modern cars. 

The die-casting process can manufacture the shell and internal structural parts of the head-up display, ensuring its lightweight and high precision.

Heads up display car

Heads up display vehicle refers to a car equipped with a head-up display (HUD), which can project driving information in front of the driver's 

line of sight to improve driving safety. Die casting plays a key role in the manufacture of the shell and internal structural parts of the head-up 

display.

Aluminum Alloy

Aluminum alloy is a general term for aluminum-based alloys, which have the advantages of lightweight, high strength, and corrosion resistance. Aluminum 

alloy die castings are widely used in the fields of automobiles, aerospace, and electronic products.

Zinc alloy

Zinc alloy is a low melting point metal with excellent casting properties and mechanical properties. Common zinc alloys include the ZAMAK series, 

which are widely used in the manufacture of small precision parts.

Zinc Alloy Metal

Zinc alloy metal refers to a group of alloys primarily composed of zinc, with other elements such as aluminum, copper, and magnesium added to improve

its properties. These alloys are widely used in die casting for their excellent fluidity, strength, and resistance to corrosion.

Zinc density

The density of zinc is 7.14 g/cm³, which is higher than that of aluminum (2.7 g/cm³) and magnesium (1.74 g/cm³).

This feature gives zinc alloys unique advantages in certain applications, such as the manufacture of small precision parts.

For more info, you can refer to: https://www.youtube.com/shorts/JLX410QV_kw

Contact LK Egypt to learn more info about the die-casting machine

LKAGENT OFFICE DCM

Address: Industry Zone, South of Port Said Kebly, Egypt

https://www.zazdiecasting.com/

Phone/WhatsApp/Wechat: +86 13598704163

Mobile: +20 101 304 3317      +20 150 181 8310

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