Die Casting Heating Solutions

2024-09-06 by Cherry

Die casting is a metal casting process that uses high

pressure to press molten metal into the mold cavity 

to obtain castings with complex shapes and precise dimensions.

The die casting process has the advantages of high production

efficiency, good casting quality, and automated production. 

It is widely used in automobiles, aerospace, electronics, 

communications and other fields.

As an important part of modern manufacturing, the die casting 

industry involves high-temperature treatment of metal materials, 

so the heating solution is crucial in the entire die casting process. 

Whether it is aluminum, zinc, magnesium and other metals, the 

efficient operation of the die casting machine is inseparable 

from scientific heating technology. This article will explore 

the die casting heating solution in depth, focusing on how to

improve the efficiency of the die casting process, improve 

product quality and extend the life of the equipment.

The die casting machine is mainly composed of a clamping mechanism, 

an injection mechanism, a hydraulic system, an electrical control 

system, etc. Its working process is as follows:

1. Clamping: The moving mold and the fixed mold are closed to 

form a closed mold cavity.

2. Injection: The molten metal is injected into the mold cavity 

at high speed and high pressure under the action of the injection

mechanism.

3. Pressure holding: After the molten metal fills the mold cavity,

a certain pressure is maintained to solidify the casting under

pressure.

4. Mold opening: After the casting solidifies, the movable mold

is separated from the fixed mold and the casting is taken out.

In the die casting process, heating plays a key role

The appropriate heating temperature can ensure the fluidity of

the molten metal and improve the quality and production efficiency 

of the casting.

What is die casting heating?

Die casting heating mainly refers to the heating process required 

for each step in the die casting process, such as melting of metal

materials, preheating of molds, and insulation of molten metal. 

In order to ensure the quality of die castings and the life of molds,

heating must be precisely controlled to avoid excessive or insufficient

heat treatment affecting the process effect.

The importance of die casting heating in the process

In the operation of the die casting machine, the heating solution 

directly determines the density, surface finish and internal structure

quality of the casting. For different metal materials, such as aluminum, 

zinc or magnesium, the optimal melting and insulation temperatures are

different, so it is necessary to select heating equipment and solutions

in a targeted manner.

1.Improve the fluidity of molten metal

The fluidity of metal in a molten state directly affects the molding

quality of the casting. By heating, the molten metal can be kept 

within a suitable temperature range, improve its fluidity, and reduce

defects inside the casting.

2. Ensure the quality of castings

The appropriate heating temperature can make the casting shrink evenly

during the solidification process, reducing the occurrence of defects

such as cracks and pores. At the same time, heating can also improve

the surface quality of the casting and make it smoother.

3. Improve production efficiency

Heating can shorten the solidification time of the molten metal and

improve the production efficiency of the die-casting machine. 

In addition, a reasonable heating scheme can also reduce the energy 

consumption of the equipment and reduce production costs.

Mold preheating

Mold preheating is an important step to ensure the quality of casting.

Unpreheated molds will cause uneven thermal stress due to sudden heating,

which will cause cracks or deformation. Correct mold preheating can 

reduce casting shrinkage and surface defects, while increasing the 

life of the mold.

Metal liquid insulation

During the die-casting process, keeping the molten metal within a 

stable temperature range helps to obtain uniform castings. Too high 

a temperature can easily lead to metal oxidation and pores, while too 

low a temperature may cause insufficient metal fluidity, resulting

in a rough casting surface or incomplete filling.

Metal melting

Metal melting is the core of the die-casting process. Modern die-casting

machines achieve efficient and precise melting processing through 

electric heating, induction heating and other methods, which not only

improves the melting speed but also reduces energy consumption.

Common die-casting heating solutions

Depending on the different metals and die-casting process requirements,

the current die-casting industry uses a variety of heating technologies,

and each solution has its own unique advantages.

1. Electric heating furnace

Electric heating furnace is a commonly used melting equipment, suitable

for most die-casting machines, especially for the melting of aluminum

and zinc alloys. Its main advantages are accurate temperature control,

easy use, and relatively environmentally friendly. Direct heating by

electric energy avoids the pollution and waste of traditional fuels.

2. Induction heating

Induction heating is an efficient way to heat metals, especially

for large-scale production. Induction heating can quickly melt 

metals and maintain stable temperatures through the principle of 

electromagnetic induction. Compared with electric heating, induction

heating is more efficient and consumes less energy, and is suitable

for frequent use in high-pressure die-casting machines.

3. Gas heating furnace

Gas heating furnace uses fuels such as natural gas, which is suitable

for large-scale production scenarios and has the characteristics of 

low cost and fast heating. However, compared with electric heating 

and induction heating, gas heating is slightly insufficient in temperature 

control accuracy and environmental protection.

4. Infrared heating

Infrared heating is an emerging die-casting heating technology, mainly

used for mold preheating. Its advantages are fast heating speed, which

can effectively reduce energy consumption, and infrared rays can directly

penetrate the mold surface to achieve uniform internal heating.

How to choose a suitable heating solution?

When choosing a suitable die-casting heating solution, you need 

to consider the following factors:

1. Material type

Different metals have different melting points and fluidity. For example, 

aluminum has a low melting point and is suitable for electric heating 

furnaces; while magnesium is more ideal for induction heating due to 

its strong activity.

2. Type of die-casting machine

Die-casting machines can be divided into hot chamber die-casting machines

and cold chamber die-casting machines, and the requirements for 

heating methods are different. Hot chamber die-casting machines 

are suitable for low melting point metals, such as zinc, and usually 

have a built-in metal melting furnace; cold chamber die-casting 

machines are suitable for high melting point metals, such as aluminum

and magnesium, and require an external independent melting furnace.

3. Production scale

Large-scale production has high requirements for heating efficiency,

and induction heating has obvious advantages in this situation. 

For small-batch production, electric heating furnaces may be a more 

economical choice.

4. Environmental protection and energy consumption

Modern manufacturing pays more and more attention to environmental

protection and energy consumption control. Compared with traditional 

gas heating, electric heating and induction heating are more environmentally

friendly and have lower energy consumption, so they are gradually

becoming the mainstream choice.

Innovative trends in die-casting heating

With the advancement of science and technology, die-casting heating 

technology is also constantly innovating. The following are several 

trends worth paying attention to:

1. Intelligent heating control

Combined with the Internet of Things technology, the heating equipment 

of the die-casting machine can achieve remote monitoring and automatic

adjustment. Through real-time data feedback, the heating system can

automatically adjust the temperature according to production needs

and improve production efficiency.

2. Energy-saving and environmental protection technology

Energy-saving technology has become a key development direction of the

die-casting industry. New heating equipment is more energy-efficient,

reduces energy consumption and carbon emissions, and is in line with

the current trend of green manufacturing.

3. Hybrid heating technology

Hybrid heating technology combines the advantages of electric heating,

induction heating and gas heating, and can switch heating methods 

at different process stages to achieve maximum efficiency and flexibility.

Conclusion

The die-casting heating solution is a key link to ensure efficient

operation of the die-casting machine and stable product quality.

By choosing the right heating technology, it can not only improve

production efficiency and reduce energy consumption, but also extend

the service life of the mold. 

With the advancement of science and technology, die-casting heating

technology will also develop in the direction of intelligence and

energy saving, helping the die-casting industry to make greater

progress in the future.

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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