Die Casting
What is Die Casting?
Die casting is a versatile process that produces engineered die cast parts through a forced high-pressure method of forcing molten metal into molds built from high grade steels. Die casting can be produced in nearly every conceivable size and shape. It provides the freedom to design intricate configurations that meet the functional requirement of the component. The die casting process produces castings with close tolerances, often eliminating the need of machining operations. Depending on your specific aluminum casting application, there are many different types of die casting processes that can be achieved.
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Industrial & Manufacturing Die Casting Applications
Die casting manufacturers can produce many interesting types of die casting applications that create parts and components that are truly unique and highly functional. Depending on your specific parameters, one type of die casting application may be more favorable than another. At SKS Die Casting, we can perform various aluminum die casting application processes based on your exact project specifications, ensuring that your part is suitable for the environment in which it will perform.
Types of Die Casting
The two main die casting processes are hot chamber and cold chamber die casting.
Cold Chamber Die Casting
Within this die casting application process, molten metal is poured into the cold chamber or cylindrical sleeve by ladle. A hydraulically operated plunger seals the cold chamber port and forces the metal into the die cavity at high pressure. Cold chamber die casting machines are used for aluminum alloys or Zinc alloys with high melting points.
Hot Chamber Die Casting
Hot chamber die casting machines are primarily used for zinc alloys, copper, lead, and other low melting point alloys. The injection mechanism of a hot chamber machine is immersed in a molten metal bath of a metal holding furnace. The furnace is attached to the machine by a metal feeding system called the gooseneck.
Advantages of Die Casting
Die casting allows for the creation of die cast parts with complex shapes and intricate designs at a price point that doesn’t break the bank. Some of the greatest benefits associated with die casting include:
- Advanced production speed
- Accurate dimensional stability
- Tight tolerances
- Variable wall thicknesses
- Fast production times
- Reduction in scrap
- Extended tool life
Materials We Die Cast
At SKS, we can perform numerous die casting methods utilizing different types of die casting materials including both aluminum and zinc alloys. Some of the advantages associated with both materials include:
Die Casting Aluminum
Aluminum casting alloys have been proven ideal for a wide range of products because of the unique combination of qualities they possess lightweight, good corrosion resistance, high tensile strength, high dimensional stability, and high thermal and electrical conductivity.
Alloy 380.0 is the most used Aluminum alloy for die casting and has been found to meet customers' various needs. Importantly, SKS can also cast Aluminum Alloys 360, 390 and 413.
Die Casting Zinc
The mechanical properties of zinc alloy die castings at normal temperatures are superior to sand castings of grey iron, brass, and aluminum, particularly in toughness and impact strength. They are much stronger, tougher, and more dimensionally stable than injection molded plastics. The reduced cost and improved properties have made it an ideal replacement for iron, copper, aluminum alloys or plastics parts.
The Die Casting Process
The standard die casting application process consists of injecting high pressure molten metal into a steel mold called a die. A complete die casting cycle can vary from less than a few seconds for small components to 2-3 minutes for a casting of over 30 lbs, making die casting the fastest technique available for producing precise non-ferrous metal parts. The following processes are routinely used to create custom die casting applications.
1. Clamping
2. Injection
3. Cooling
4. Ejection
5. Trimming
Excess material and flash must be trimmed from the channels of the die due to solidification during the casting process. This is accomplished either manually or through the assistance of trim die. a saw, or trimming press. The scrap material that results from this trimming is either discarded or can be reused in the die casting process.
