Ever wondered how to manufacture complex automotive parts like engine blocks, powertrain and suspension components? Contrast these bulky components with lightweight components such as surgical tools in the medical industry. High pressure die casting is a popular manufacturing process used to create this range of products.
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What is the high pressure die casting aluminum alloy process, please see the answer below,
The aluminum alloys are melted in a furnace that is separate from the die-casting equipment.
Then carry the molten aluminum into the equipment’s shot sleeve using a manual or robot arm-operated ladle.
Next, the piston will push the molten metal with high pressure to fill the mold. Now, leave the casting inside the dies for a specified period to cool down and solidify.
Finally, separate the die halves, and retrieve the completed casting.
High pressure die casting aluminum alloy process :
1. Mold preparation
At the beginning of the production cycle, the die-casting mold is cleaned to remove impurities. Then lubricate the inner wall of the mold. This regulates the temperature of the mold and facilitates the removal of the cast product.
2. Injection
The molten metal is poured into the injection chamber, which then injects them into the mold. There are 2 ways to make this injection process happen. These are hot chamber and cold chamber injection.
Hot cell injection
In this method, the injection system is immersed in the melting furnace. Molten metal enters the nozzle through the injection plunger and then into the mold. This method works for metals such as zinc, magnesium and lead.
Cold room injection
In this method, molten metal is poured into a cold chamber sleeve by hand or through an automatic device. The hydraulic plunger is then forced through the sleeve. This plunger seals the port and forces the metal into the mold. Once solidification is complete, remove the plunger and open the mold to eject the cavity. This method is suitable for high melting point solids such as aluminum, brass, and magnesium. Additionally, the cold chamber process uses either horizontal injection or vertical injection.
Magnesium can be used in both cold chamber and hot chamber injection processes. Typically, small and complex parts are produced with hot chamber machines because of the size limitations of these machines. Additionally, high-pressure zinc die-cast parts are generally smaller than aluminum die-cast parts.
3. Parts disassembly
After making sure all the molten metal has solidified, remove the cavity from the mold. The ejector pin releases the cavity. The ejector pin is usually located at the free end of the mold and is used to push the solidified casting out of the cavity.
4. Pruning
The final step in high-pressure die casting is to remove excess material from the product and mold. Pruning dies, saws, etc. can aid in the pruning process. In addition, the metal scrap can be reused and recycled in subsequent production cycles.
Production line
Advantages of High Pressure die casting Aluminum alloy
High-pressure die casting is a popular process across various industries as it offers several advantages over other manufacturing processes. Here are some of the advantages.
– Higher productivity
The high-pressure casting process is more productive than low-pressure or gravity casting. Using high pressure allows molten metal to be injected at high speeds, thereby increasing productivity. Hence, making this process popular in high-volume manufacturing.
– Make quality parts
Apart from this, high pressure casting offers good quality in terms of dimensional accuracy and excellent surface finish. High-precision products do not require additional trimming processes, which can be time-consuming and costly. Good surface finish simplifies the plating process. In addition, the advantages of high-pressure die-cast products include excellent uniformity and optimal mechanical properties.
– Thin wall products
The high pressure in this die-casting process allows for thinner cross-sections than any other casting process. Depending on your requirements and component size, wall thicknesses below 0.40 mm can be obtained. Thin walls help reduce product weight. It also allows inserts (also known as "co-cast" parts) such as screws and liners to be added to the product during the casting process. Therefore, it helps to reduce the number of components in the assembly process.
– Implement complex designs
The die casting process allows a variety of mold shapes to be used. The flexibility of the mold shape means that complex parts can be produced during the casting process, thus facilitating complex assemblies.
– Durable mold
The molds used in this process are long-lasting, meaning they can be reused across multiple production cycles. This reduces the die casting cost per unit of product.
High pressure aluminum die casting applications
Due to the superior quality of the products obtained through HDPC, the process has found various critical applications in several industries.
- Automobile industry
High-pressure die casting can produce various aluminum and magnesium automotive structural parts. It produces structural components such as engine blocks, transmission housings, oil pans, engine mounts and cross members.
- Medical industry
It is also a popular technology in the medical industry for producing lightweight surgical tools. In addition, medical equipment and high-yield imaging equipment, infusion pumps, etc. are also manufactured using the HPDC process.
– Aerospace industry
This process is very popular in the aerospace industry due to its ability to manufacture complex and sophisticated designs and automation. Aluminum, zinc and magnesium alloys are used to make engine parts for aerospace applications.
Q1. Why is it called die casting?
The reason is that the process uses molds. The mold is a steel mold that is mainly CNC machined with liquid metal injected into it. It is divided into two halves: a fixed half connected to the casting machine and a movable ejector half.
Q2. How does die casting differ from other casting production methods?
Die cast parts offer many of the same advantages as gravity cast products, such as the rigidity, look and feel of solid metal; tested fatigue strength properties; good sound isolation; and built-in EMI shielding for electronic applications. However, die casting in particular allows for rapid production with excellent dimensional accuracy, which often eliminates the need for all machining. Additionally, sand casting requires a new mold for each production, and permanent mold casting is slower compared to HPDC casting.
Q3. What is the difference between low pressure and high pressure die casting?
The pressure range of LPDC is between 0.08-0.15 MPa, while the pressure range of HPDC is between 30-70 MPa. LPDC has average productivity and slower casting cycles. HPDC, on the other hand, has higher productivity and faster casting cycles. HPDC produces products with porosity and good surface finish. LPDC, on the other hand, does not produce pores inside the casting, but its surface finish is average.
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