You May Want To Know About Aluminum Die Casting Process.

Aluminum Die Casting Process

Aluminum die casting is a process where we use reusable molds and molten aluminum to produce complex parts. The alloys are shaped by forcing molten Aluminum under high-pressure into the dies cavity.

Machines Used in Aluminum Die Casting Process

Two types of machines are widely used in this process, hot chamber die casting and cold chamber die casting. The procedure of them doesn`t differ much from one another. However, depending on the alloys and parts, the right machines are chosen.

Hot Chamber Die Casting

Hot chamber machines are used for alloys with low melting temperatures, such as zinc, tin, and lead.This machine is most suitable for materials that have a low melting point. The hot chamber is not suitable for materials with a higher melting point because it would damage the machine`s pump.

Cold Chamber Die Casting: These machines are better for metals that have a high melting point like aluminum, magnesium, etc. The process of both machines is quite similar. Although with cold chamber machines there is no chance of damaging the pump with high temperature.

The Actual Process:

• Set up mold: This is the first step of starting the die casting process. First, We need to check if the mold is made perfectly according to the design. Cleaning the mold before work is necessary as well.

Then we install or set up the mold inside the machine and make sure they`re closed and clamped with appropriate force. The force should be strong enough to stick both halves of the mold, so it doesn`t open during the process.

• Die casting parameter setting: In this stage, we set up the parameters of the machine. The accurate parameters allow the machine to maintain an accurate measurement throughout the process.
• First article inspection: After the sample is approved and the mass production has begun. We randomly chose a set of parts and inspect it. The name may apply that only the first produced parts are taken into inspection, but that`s not quite right. Parts can be taken randomly from any initial production and taken into an inspection to see if there are any defects in the mass production parts.This is to ensure that the final products are error-free and if there are any errors to be found, the error is fixed immediately and the production gets restarted.
• Lubrication: Lubricates helps the parts to be ejected from the dies. Although lubrication is not required before every cycle, it`s advised to apply lubrication in the beginning and after a couple of cycles to make the process smoother.
• Clamping: Clamping enables the die halves to be closed tightly. Because the die halves aren`t closed tight and is loose, there will be defects in the final products. Clamping should be ensured that it leaves no space and closed the die halves tightly with a strong force.

• Injecting the molten metal: In this stage, the molten metal which is then in the furnace at a controlled temperature, moved into a shot chamber. Which allows it to be easily injected into the die.Once the molten metal is in the shot chamber, it gets injected with an injection ram into die for solidifying. The pressure holds it into the die cavity and it`s maintained throughout the process.
• Cooling process: The molten metal starts to cool down when it enters the die cavity and begins solidification. Which enables it to take into the shape of the dies. The die halves cannot be opened until the cooling is complete and the molten metal turns into solid metal.The cooling time can be longer for parts with thicker walls or complex design and vice versa.
• Ejection: When the parts are cooled off sufficiently we can open up the die halves. When it`s opened, the ejection system pushes the casting out of the die cavity. And this how the parts are removed from the machine. After that, the die halves are ready for the next cycle.
• Edging or Trimming: With the die casting process, there is always excess material attached to the parts. We need to cut it and make them smooth before final use or delivery.
• Last article inspection: Almost similar to the first article inspection, the only difference is that it`s conducted on the last batch of final products. To ensure that the right quality and error-free products are being delivered to the buyers.

Benefits of Aluminum Die-casting process

This process is widely popular among many industries worldwide today. The reason behind this is simple, companies want products that meet their requirements precisely. And there are not a lot of options that can meet the requirements as aluminum die casting can.

Industries like marine and medical need their products to be very accurate and identical to their design. And with this process, you can get 100% accurate products according to the design. The reason is that the process is completely automatic and operated by a computer. There is no scope for errors and mistakes. All the parts and products manufactured from this are identical to each other.

On the other hand, companies like automotive and aerospace want their products to be lightweight and fit with their other parts accurately. Fortunately, with aluminum alloys, the final products are very lightweight and suitable for any industry. But the lightweight nature of aluminum doesn`t reduce it`s quality at all.

Other than that, it`s a corrosion-resistant ability, weight strength ratio is very high compared to other processes or alloys. Which makes them even more favorite among buyers.

One other important factor we need to consider is that, if you`re ordering goods for your company, you always want two things, first- low cost, and second- low lead time.

And with this process, you can have both opportunities. Compared to metal die casting or other alternatives aluminum die casting is relatively very fast to manufacture and the cost is very minimal.

If you`re associated with an OEM/ODM company and need a bulk amount of customized products, aluminum dies casting can be the best choice for your company.

The fast production, multiple finishing, and simple assembly make it even more acceptable and preferred process to manufacture bulk amounts of parts for companies like yours.

Well, that's all for today. If you want to communicate with me or place an order, you can contact me.