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Category Archives: Diecasting Process
Porosity in Aluminum Die Casting Parts
Aluminum Die Casting Parts Porosity – Porosity in Die Castings
There are many forms of Die Casting Porosity, many are caused by these die casting variables:
- Metal Temperatures and Mold Temperatures.
- Material Cleanliness.
- Die Casting Mold Design.
- Die Casting Part Design.
- Die Casting Machine Pressures.
- Die Casting Machine Shot Speed.
- Die Casting Spray or Die Casting Mold Release.
- Other forms of porosity can be from “shrinkage” or wall thickness.
What is Die Casting Porosity? In order for you to know what die casting porosity is, you need to know the die casting basics. The most common form of Die Casting Porosity is a kind of factory defect in which die cast parts contain small pockets of void space and air within the metal, causing it to become porous.
Porosity in Die Casting is the air trapped by the metal inside the die casting parts. To know more, a basic knowledge of the die casting process is necessary. Die casting is a process wherein a particular amount of molten metal is put inside a shot cylinder, then it is applied (plunged) with great force with a piston so as to force the metal into a die cast mold or die cast die. During this “plunging process”, air inside the cylinder is forced along with the metal into the die casting mold. It is a very fluid turbulent process. The air forced into the mold with the metal and the metal already inside the mold is forced out of the mold through a series of gates, vents and overflows.
After this, the metal is left to cool down and harden or freeze inside the mold. The metal is then removed as a die cast part. The same process is repeated over again.
Die casting companies use metals which are non-ferrous, or do not contain Iron, as this is the highest factor for oxidation and rusting. Several examples of non-ferrous metals include zinc, aluminum, lead, magnesium, tin and copper. Kinetic Die Casting only uses aluminum and zinc.
In the worst case, porosity in die casting parts, weakens die casting parts, if the voids or pockets are very large. Porosity typically matters most in pressure tight die casting parts. When the air escapes through a die casting part, it is typically caused by porosity.
Employees of Kinetic Die Casting are POROSITY EXPERTS in die casting parts that need to be free of porosity.
See webpage: http://www.kineticdiecasting.com/porosity.html
Kinetic Die Casting Company can manufacture aluminum car parts, aluminum hardware, and Aluminum Lighting Partsaluminum lighting parts
Posted in Die Casting Parts, Diecasting Process, newsletter
Tagged die casting, Die Casting Parts, Porosity
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Draft Angle in Die Castings
Aluminum Die Casting Parts Draft Angle – Draft Angle in Die Castings
When someone asks me “what is draft angle in a box?” or “why do I need a draft angle on my aluminum die casting box part?” The technical answer is, all aluminum die castings require a draft angle on the walls of die cast box parts perpendicular to the parting plane or parallel to the slide interfaces. Since I have selling die cast parts for over 20 years, I find simple answers and provide simple calculations for my customers. What does that mean to the typical engineer (any engineer other than tooling or mechanical) or professional buyer?
I try to give examples that most people can relate to, because most people do not have a need to concern themselves with how things are made, only what is made, and will it be what they need. I ask, “Have you ever noticed on a cupcake the bottom diameter is smaller that the top diameter?” or “Have you noticed that a cake pan has sides that slope in toward the middle of the pan?” That would be an extreme example of a draft angle. Aluminum die castings would stick inside the die casting tool, molds, or die casting die if there was not enough draft angle in the tool and part. The typical draft angle for an aluminum die casting part is two degrees per side. The calculation for that is simple if a person is familiar with die casting production part design, but is not familiar to most people.
Picture an enclosure (or Aluminum Box) sitting on a table with the open side up. The aluminum box is 2″ deep inside with the height and width 4″ each way on outside. The walls of the box are 0.10″ thick. Due to the wall thickness, a few things are evident to a part designer concerning this simple box:
- The overall height of the box is 2.10″ tall.
- The interior of the box at the top of the opening is 3.80″ x 3.80″.
A 2 degree draft angle will change the dimensions in the following on the interior and exterior and should be considered if something needs to fit inside the box or outside the box:
- The top inside dimension of the box will be 3.80″ and the bottom inside will be 3.664″
- The top outside dimension of the box will be 4.00″ and the bottom outside will be 3.864″
If the box was designed for the interior of 4″ x 4″ at the bottom: box:
- The top inside box dimension needs to be 4.136″
- The outside top box dimension will be 4.336″.
See webpage: http://www.kineticdiecasting.com/draft.html
Kinetic Die Casting manufactures a lot of aluminum rooftile plates , trim tile molds, and military die casting. If you would like a quote, please visit our website: Kinetic Die Casting Company
Sand Casting Compared with Permanent Mold Die Casting
Sand casting compared with Permanent Mold Die casting
Sand casting and die casting are both the manufacturing process to produce cast parts by pouring molten liquid metal into the Permanent Mold, which contains a empty cavity of the desired design, and then allowed to solidify. The main difference between sand casting and Permanent Mold die casting is in the mold.
The sand casting is a cast part produced by shaping a mold from a sand mixture and pouring molten liquid metal into the cavity in the mold. The mold is then cooled until the metal has solidified.It is expendable mold casting.
Die casting is the process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from nonferrous metals, specifically zinc, copper, and aluminum based alloys, but ferrous metal die castings are possible. It is non-expendable mold casting.
Non-expendable mold casting differs from expendable processes in that the mold is not required to be reformed after each production cycle.
The sand casting is one of the most well-liked and simplest types of casting that has been used for centuries. Sand casting allows for miniscule batches to be made compared to permanent mold casting and at a very tolerable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very small size operations.
The die casting method is especially suited for applications where many small to medium sized parts are needed with good detail, a fine surface quality and dimensional consistency. In recent years, injection-molded plastic parts have been substituted for some die castings because they are cheaper and lighter. Plastic parts are a practical alternative if hardness is not required and little strength is needed.
To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.
Kinetic Die Casting manufactures a lot of aluminum rooftile plates , trim tile molds, and military die casting. If you would like a quote, please visit our website: Kinetic Die Casting Company
U.S. Manufacturing, We’re ‘Playing Catch-Up’
Scott Paul, the executive director of the Alliance for American Manufacturing (AAM), applauded the direction that the United States is taking with the newly created Advanced Manufacturing Partnership. The group will be led by top engineering universities and several major U.S. manufacturers.
Last week, President Obama also directed the National Economic Council and the Office of Science and Technology Policy to work with the new partnership to implement a number of the recommendations of the President’s Council of Advisors on Science and Technology.
“We are playing catch-up on initiatives where we have public-private partnerships to try and spur manufacturing,” Scott said during an interview on C-SPAN. One particular area that is well-suited to joint efforts is in bringing new technology to the factory floor, Scott asserted. “That is a perfectly appropriate role for the government,” Scott said. Other countries are currently involved in these efforts and the U.S. was as well during the 80s. “This will help keep good-paying advanced-manufacturing jobs in the U.S.”
The group supports a national manufacturing strategy.
“The idea of a manufacturing strategy or industrial policy is hardly a radical concept,” the group says. “Alexander Hamilton constructed America’s first industrial policy in 1791. Setbacks during the War of 1812 due to a lack of domestic capacity to build naval vessels and military equipment cemented the determination of the federal government to grow manufacturing, a policy that continued until the end of World War II. Today, globalization and such economic approaches as a strong dollar policy favoring domestic consumption have helped to steadily erode manufacturing as a percentage of gross domestic product, as well as private-sector employment and other key measures.”
During the interview, he discussed the “Made in America” movement and other topics including the currency issue with China.
-Industryweek
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Solving Problems of Porosity in Die Casting Parts
Solving Problems of Porosity in Die Casting Parts. Porosity in die casting parts is an important issue in metal-working. Porosity, in the science of materials, refers to the presence of gaps or bubbles inside a metal structure. High porosity tends to weaken the final product. Metal parts production companies are given certificates depending on strength, durability and reliability of their products. Hence, this defect must be minimized.
To fully understand this concept, one must be aware of the metal-shaping process behind it. Die casting is a method that uses high pressure to shape a molten metal. For example, zinc is heated on a furnace to reach its melting point. Then, it will be shot to fill the gap between two dies. That gap is the mold, which contains the shape and details of the final product. As the lump of zinc solidifies, pressure of up to 175 mega Pascal is exerted through the dies. If gases are accidentally mixed during this speedy process, they will result in porosity in die casting parts.
There are three levels of porosity in finished metal parts. The first two levels are acceptable, depending on the expected usage of the part. The third level means that the object is highly porous. There are large gas bubbles inside that will weaken the product against tension.
Most of the time, it is impossible to achieve a 100% pure metal piece if die casting is used. Porosity in die casting parts can be minimized by thoroughly cleaning the dies before operations. Pressures and temperatures must also be matched with the type of metal and intended purpose of the part.
To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.
Kinetic Die Casting makes great quality aluminum, and Zinc Die Casting If looking for a job or would like a quote please visit our website:Kinetic Die Casting Company
Posted in Diecasting Process
Tagged aluminum, Aluminum Die Casting, Aluminum Die Casting Company, aluminum parts
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