High Pressure Die Casting Process Applications

2024-08-22 by Cherry

‌High-pressure die casting, also known as high-pressure

casting is a casting method that pours liquid or

semi-liquid metal into the die-casting mold cavity and

rapidly solidifies the metal by applying high pressure.

This method is mainly used to produce metal parts with

complex shapes, high precision, high strength, thin walls,

and lightweight.

High-pressure die casting has the advantage of high-production

efficiency, high precision, and diversified product material

selection, which can achieve rapid prototyping, improve

production efficiency, and reduce production costs.

Due to the injection of high pressure, die castings have high

dimensional accuracy and surface finish, and can produce parts

of various complex shapes and structures, which are suitable for

large-scale production. This process is suitable for various

metal materials such as aluminum, zinc, and magnesium.

High-pressure die casting is an efficient casting method that

is widely used in various industrial fields, especially in the

manufacture of automobiles, aerospace, and consumer electronics.

This article will explore in depth the application, technical

characteristics, and practical applications of high-pressure

die casting in different fields to help users better understand

and apply this process.

What is high-pressure die casting?

High-pressure die casting is a casting method that injects molten

metal into the mold cavity at high pressure.

The key to this process is the use of a high-pressure LK casting machine

(also known as a die-casting machine), which can quickly fill the

molten metal into the mold in a short time, thereby obtaining

high-precision, high-quality castings.

In the high-pressure die-casting process, CAE simulation

software is increasingly used, such as PROCAST,

MAGMA, FLOW-3D, etc., which are used to predict defects such

as air entrainment, inclusions, and poor filling, greatly improving

the yield rate and saving costs. In addition, the application of vacuum

die-casting has also been well developed.

The filling and airtightness problems of castings are solved by

vacuuming, which improves product quality.

The main steps of the high-pressure die-casting process include:

1. Melting metal: heating alloy metals (such as aluminum alloys,

magnesium alloys or zinc alloys) to their melting point to make

the liquid.

2. Injection: Using a die-casting machine to inject molten metal

into the mold at high pressure. The pressure usually reaches

hundreds to thousands of bars.

3. Cooling and solidification: The metal cools and solidifies

rapidly in the mold to form the desired casting shape.

4. Demolding: After the casting is cooled, it is removed from

the mold for subsequent treatment or processing.

Advantages of high-pressure die-casting process

The high-pressure die-casting process stands out among many

casting methods with their unique advantages:

1. High precision and good surface quality: High-pressure die-casting

can produce castings with precise dimensions and smooth surfaces, 

reducing the need for subsequent processing.

2. High production efficiency: Due to the fast casting speed,

high-volume production can be achieved, which is very suitable

for large-scale production.

3. Excellent mechanical properties: Die castings generally have

excellent mechanical properties, including high strength and

durability.

4. Casting of complex shapes: High-pressure die-casting can produce

complex and fine castings, which are suitable for various complex 

design requirements.

Application areas of high-pressure die-casting

The application areas of high-pressure die-casting process are very

wide, including but not limited to automobile manufacturing, home

appliance manufacturing, construction industry, etc.

For example, the manufacture of automobile engines, chassis, 

gas cylinders, and other parts, the manufacture of various

home appliance parts such as washing machines and refrigerators,

and the manufacture of building decorations, doors, and windows,

railings and other parts. In addition, this process is also widely

used in the manufacturing of parts in the fields of medical

equipment, aerospace, and shipbuilding.

The following are some major fields and their specific applications

1. Automobile industry: Automobile manufacturing is an important

application field of high-pressure die-casting process.

High-pressure die-casting is often used to produce automobile

engine cylinder blocks, transmission housings, wheel hubs, and

other parts. These parts require high strength and durability

to ensure the overall performance and safety of the car.

2. Aerospace: In the aerospace industry, high-pressure die-casting

is used to produce lightweight and high-strength parts such as

aircraft fuselages and engine parts. 

These parts need to withstand high loads and have excellent

corrosion resistance.

3. Consumer electronics: With the complexity of electronic

product design, high-pressure die-casting is also increasingly

used in the field of consumer electronics.

It is often used to manufacture mobile phone housings, laptop

computer housings, etc. These products require high-precision

and excellent surface effects.

4. Home appliance manufacturing: High-pressure die-casting

is also often used to produce structural and decorative parts

in home appliances such as washing machines, refrigerators, and

air conditioners. This process can ensure the high-quality and

durability of the product.

5. Mechanical equipment: In the field of mechanical equipment,

high-pressure die-casting is used to produce various mechanical

parts, such as gearbox housings, support frames, and connectors.

These parts require high strength and wear resistance to adopt

to harsh working environments.

Although the high-pressure die-casting process has many advantages,

it also has some limitations, such as it is not suitable for the

production of large, heavy, or precision parts. In addition,

the mold cost is relatively high because the design and

The manufacture of the mold requires high technology and costs.

Moreover, due to factors such as mold wear and thermal expansion,

the size of precision parts is difficult to guarantee.

Despite this, the high-pressure die-casting process is still an

indispensable and important technology in modern industrial

production.

Selection and maintenance of high-pressure die-casting machines

Choosing a suitable high-pressure die-casting machine is crucial

to the successful application of high-pressure die-casting processes.

Here are some key points for selection and maintenance:

1. Choose a suitable die-casting machine: According to production

needs, choose a suitable die-casting machine model, including 

its injection capacity, clamping force, and mold size.

Consider the complexity, size, and production volume of 

the casting.

2. Regular maintenance: In order to ensure the normal operation

of the die-casting machine and extend its service life, regular

maintenance and maintenance are required. Including checking

the hydraulic system, electrical system mold, etc. to ensure

the stability and safety of the equipment.

3. Optimize process parameters: According to the specific

requirements of the casting, adjust the process parameters

of the die-casting machine, such as injection pressure,

injection speed, and cooling time, to optimize the casting

quality and production efficiency.

4. Train operators: Ensure that operators are professionally

trained and understand the operating procedures and maintenance

methods of high-pressure die-casting machines to improve

production efficiency and reduce the occurrence of failures.

Future development trends

In the future development, the high-pressure die-casting process

will develop in a more efficient and environmentally friendly

direction:

1. Material innovation: The research and development of new

alloy materials will enable the high-pressure die-casting 

process to be applied to more fields and provide better

performance.

2. Energy-saving technology: The application of energy-saving

technology will reduce energy consumption in the production

process and improve production efficiency.

3. Intelligent control: The introduction of intelligent control

systems will enhance the automation of die-casting machines

and further, improve production accuracy and reliability.

4. Environmentally friendly process: The promotion of environmentally

friendly die-casting processes will reduce waste and pollution

in the production process, in line with the needs of sustainable

development.

In short, high-pressure die-casting technology has become

an indispensable and important process in modern manufacturing

industry with its high precision, high efficiency, and wide

application fields. 

By rationally selecting equipment, optimizing the process

parameters and constantly paying attention

to technological development, enterprises can give full play to

the advantages of high-pressure die casting technology and

achieve more efficient and higher quality production goals.

For more info, you can refer to: 

https://www.tiktok.com/@lk_diecastingmachine/video/7405113006880820522 

https://www.youtube.com/shorts/JLX410QV_kw

To learn further info about Die Casting Machines,

pls contact LK Die Casting Machine Authorized Official Agent

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