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Category Archives: Diecasting Process
Exploring the Process of High Pressure Die Casting
Exploring the Process of High Pressure Die Casting. The process of high pressure die casting is one of the fastest and cost effective methods in shaping metal products. Many manufacturing companies in the fields of automotive, aircraft and electronics use die casting as the primary metal working procedure. It produces high quality products with strong yield and fine finish. It provides strength treatment which is far better than forging, extrusion or sand casting.
The procedure involves two dies: the cover die half and the ejector die half. Between them is the mold cavity. When the dies are fitted together, the plane of intersection is called the parting line. During metal working, molten metal is forced to the mold through an opening in the cover die. This is done with very high speeds, due to the high pressure of injection. These are called “shots.” While the metal is still in liquid form, extreme pressure is applied, compressing the dies. This will be maintained until the metal solidifies.
The process of high pressure die casting is further divided into two groups: cold chamber and hot chamber processes. Basically, both employ high pressure shooting and compression of the molten metal. However, hot processes can only be used on metals with lower melting point. These include copper. Cold processes are used on high melting point metals like aluminum and magnesium. Cold processes take a relatively longer time before the shot is compressed at the dies.
In both methods, the process of high pressure die casting is consistent in producing tough products. They are highly resistant to torsional and tensional stresses, making die casting popular in multiple industries.
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 aluminum military parts, aluminum hardware, and aluminum die castings. Visit our website for a quote: Kinetic Die Casting Company
On Die Casting Parts Production: Can I Get Custom Metal Parts or Prototype Parts?
On Die Casting Parts Production: Can I Get Custom Metal Parts or Prototype Parts? “Can I get custom metal parts or prototype parts?” This might be the question that you will probably ask out after you have convinced yourself to try the metal die casting parts for your enterprise. In most cases, the answer is yes. Of course, there are dedicated die casting companies that will allow you to see the protoype parts of what you intend to order from them. This is being done by the said firms in order for you to assess the parts physically before they run the mass production.
Prototype and custom metal parts are obtainable for a variety of options. The first one is through the SLA process. SLA is spelled as “Stereo Lithography”. In this process, the prototype parts are created from a plastic that is highly fragile. The parts may easily break when dropped.
The next option is through the prototype castings. Here, a unique SLA is used as a pattern for creating several castings. Unlike with the above process, the prototype castings use metal instead of plastic. The prototype parts almost resemble the design of the original parts that have been requested.
Generally, the prototypes are produced within four to six weeks. They are later delivered to the clients for assessment. Custom parts are also available through a process called CNC machining. The custom parts are often manufactured from heavy-duty metals.
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 is a die casting company specializing in aluminum and zinc parts. If you would like to request a quote, please visit our website:Kinetic Die Casting Company
Brass Die Casting Parts
Copper alloy die castings (Brass Parts Die Castings) have the highest mechanical properties and corrosion resistance of all die casting parts. Because of high metal temperatures and shorter die casting mold life, die casting brass has not been readily accepted as a good die castings alloy. Of the diecast brass alloys, the yellow brass die casting alloys are the most commonly die cast in this country and overseas. Advantages of brass parts die castings, as with other die casting alloys, include good surface finish, precise dimensional control, and high production rates.
In the die casting of brass parts, induction brass melting usually is preferred. This form of melting will produce less melt loss through dross formation, faster melting, better control of brass composition and temperature, and less gas absorption by the metal. Speed of the brass melting also is important, to reduce vaporization of volatile alloying elements—particularly zinc.
Fluxes are not always required in melting diecasting brass alloys. However, since dirt is unavoidable present, some fluxes may be advisable to assure cleanliness of the molten brass metals. A typical flux consist of three pounds of anhydrous borax and one pound of silica per hundred pound of brass metal.
Whether melting for brass die casting is performed under oxidizing or reducing conditions (induction melting is oxidizing), it is preferable to keep gas absorption at a minimum, because the absorbed gas must be removed prior to pouring. When die casting brass melting is done in a neutral atmosphere, a protective cover (usually, charcoal) must be used to prevent further absorption of oxygen and hydrogen. Dissolved hydrogen is removed from the molten metal with and inert gas (usually, nitrogen).
Cold chamber die casting machines used for die casting other die casting alloys are suitable for brass alloys. Diecast Ram pressures range from three thousand to ten thousand psi. Speed of the die casting plunger may vary from ten to two hundred and fifty psi. Regulation of speed, pressure, gating, venting, and die temperatures are essentially the same… and influence the quality of the die castings the same as with aluminum die castings and zinc die castings.
Tungsten hot work tool steels (H-20, H-21 and H-22) heat treated to Rockwell C38 to C45 are more commonly used for die casting molds and cores used for die casting brass. Moving parts not exposed to molten brass metal can be made of H-13 or 6145 heat treated to Rockwell C40 to C50.
The surface finish on die casting mold cavities must be satin or matte for purposes of surface tension. For die casting thin-wall parts, a die casting mold life of 40,000 to 50,000 shots can be expected, in yellow brass die cast parts. For alloys requiring higher metal temperatures, die casting mold life can fall to 10,000 die casting parts.
In die casting brass, the die cast mold life usually is given higher consideration than surface finish of the casting. If temperatures are too low, scrap parts are produced. If the die temperature is too high, blistering will occur. Normal diecasting mold and core temperatures are between 600-1300F. Oil or water usually is circulated through the die to control die temperatures. Die lubricant is used sparingly in die casting brass, since lubricant has the tendency to burn into the brass part casting and result in defective die cast brass parts. Generally, oil and/or graphite is used on die casting plunger tips or a spot where release of the diecasting is a problem.
Normally, scaling of the dies used in diecasting brass is common and the die has to be removed from the die casting machine (perhaps every eight hours) and polished. Repeated cleaning will cause dimensional changes… and where dimensions are critical, machining of the brass die casting may become necessary.
The most important factors in the die cast production of brass die castings are shape, weight, quantity, and likely replacement orders, for providing and informed quotation. Die casting defects, mis-runs excessive porosity, and flow lines are among the pitfalls. A proper balance of brass metal temperatures, diecast die temperature, venting and gating must be achieved to solve or eliminate the defect problem.
Because of the poor diecast mold life experienced in die casting brass parts or other copper alloys—in addition to the cost of the alloys, themselves—the copper alloy castings cannot be as price competitive as aluminum, zinc, or magnesium die castings. The copper-alloy die casters, however, provide a process where quantities of superior diecastings are produced that are not otherwise obtainable by other processes.
Kinetic Die Casting Company
http://www.kineticdiecasting.com/brass_die_casting.html
Kinetic Die Casting is located in Southern California. KDC specializes in aluminum and zinc die casting tooling. If you would like a quote, please visit our website:Kinetic Die Casting Company
Posted in Die Casting Parts, Diecasting Process
Tagged die casting, Die Casting Company, Diecasting Process
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Minimizing Porosity in Die Casting Parts
Minimizing Porosity in Die Casting Parts. Die casting is popular method for machining metal parts for vehicles and electronics. When this method is applied, tough and well-detailed products are produced. However, due to large capital costs of the dies, die castings are preferred only for large scale operations. One important issue in this industry is the tracking of porosity in die casting parts.
In order to understand the concept of porosity in metal working, one must first understand the basics of die casting. Hot or molten metal is forcefully injected into a cavity, at pressures from 10 to 175 mPa. The cavity is then applied with that pressure until the metal freezes or solidifies. The mold cavity is made by two contacting parts: the cover half and the ejection half.
The pressure of injecting the molten metal results in high processing speed. It also induces uniformity, inside and out, of the finished product. However, air in the injection tube mixes with the molten metal during this speedy process. The trapped air bubbles in the product are called porosity in die casting parts. This is often considered a factory defect. If the bubbles are large or interconnected, they can cause loss of tensile strength in the final product.
There are several factors that affect porosity in die casting parts. The manufacturer must be sure that the molten metal is free from impurities and that the molds are clean. The working temperature of the furnace must also match with the metal being processes. Other factors include shot speed, lubrication and amount of pressure.
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 is a california die casting company that manufactures die cast parts. If you would like more information or request a quote, vist our website:Kinetic Die Casting Company
For Large Scale Industries: The Process of High Pressure Die Casting
For Large Scale Industries: The Process of High Pressure Die Casting. The process of high pressure die casting is popular among large scale production lines. It is considered as one of the most cost effective and fastest metal working process, when compared to forging, sand casting and other types of machining. Traditional die casting is also called high pressure die casting because the molten metal is forced into the mold cavity by using high pressure.
The mold cavity is formed by two halves. They are the cover die and the ejector die. The section where the two halves meet is called the parting line. During casting, molten metal is injected between the dies. The metal is allowed to flow through an opening in the cover die half. High pressure, between 10 to 175 mPa, is maintained until the molten metal solidifies. This process of high pressure die casting ensures uniform solidification of the final product. Hence, it produces uniform work pieces with high yield strength. There are two types of the method: cold chamber and hot chamber casting. The choice depends on the melting point of the metal. For example, zinc and aluminum alloys can only be processed in cold-chamber environments.
The process of high pressure die casting has many applications, ranging from the toy industry to automotive and computers. The technique also minimizes, if not totally eliminates, post-machining like sanding or grinding. Therefore, there are less post-production costs. However, this technique is only recommended for large scale businesses. The initial cost of construction of dies, due to painstaking details and strength, is relatively higher than other machining processes.
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 aluminum die castings creating aluminum die casting boxes, aluminum handle hardware, and aerospace die casting. If you would like to get a quote, please visit our website: Kinetic Die Casting Company
Kinetic Die Casting manufactures products like heatsink die casting, aluminum housings, and lighting fixtures. If you would like more information, please visit our website:Kinetic Die Casting Company
