Kinetic Die Casting Company makes Aluminum Lighting Parts. The fact that Kinetic Die Casting Company makes Aluminum Lighting Parts is good news. Lighting parts made of aluminum is great for the home and the workplace. Aluminum is lighter than steel …
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Tag Archives: Diecasting Process
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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Applications of Metal Working: Die Castings Used for Trucks
Applications of Metal Working: Die Castings Used for Trucks. Die casting is a popular method for cutting and shaping metal for industrial and commercial purposes. Die castings used for trucks is a good example. In the field of transportation equipment, safety is of the highest priority. This can be accomplished by having strong machine components and frames. Of course, they must have the right specifications down to the nearest fraction of a micrometer. Die casting satisfies all these requirements.
In die casting, molten metal is forced rapidly to take the shape of a mold. Then, high pressure (starting at 10 mega Pascals) is exerted until the metal cools and solidifies. Then, using ejector pins, the finished product will be released from the mold. Traditionally, sand casting is used to create die castings used for trucks. However, high pressure die casting produces finer products. They also produce higher resistances to multi-directional stresses.
A good example of a part processed this way is the engine block. Most trucks have engines which are made from magnesium and aluminum. Aluminum is a very light metal, with high resistance to corrosion. Magnesium is very tough, with a high strength to weight ratio. Both of these metals have relatively high melting points. They are die-casted in a cold-chamber system, which further increases their yield strengths.
Die castings used for trucks also include smaller parts like sprockets, rods and gears. Large scale die casting can also be used for chassis and frames. They can be die-casted into individual rods and sheets. Then, they will be welded or assembled together.
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 utilizes die casting to manufacture parts like aluminum car parts, airplane parts, lighting parts and much, much more. If you would like to request a quote, please visit our website:Die Casting quote
Metal Working Applications: Die Castings Used for Buses
Metal Working Applications: Die Castings Used for Buses. Die Castings used for buses is an important application of die casting. When you are riding a bus, try to look around. Most of the metal works here are made from high pressure die casting. If the article itself is not a product of die casting, then it is probably connected or attached to something that is. That makes this metal-working method very important to the transportation sector.
Die casting is a metal-shaping process, which involves two contacting cavities called dies. A controlled amount of molten metal is allowed to fill this cavity. Then, strong pressure will be maintained, pressing the molten substance, until it solidifies. The process creates a very tough finish product, with a yield of about 69%.
Die castings used for buses include pipe fittings. You can see them connecting horizontal handle bars near the roof of the bus. Fittings also connect vertical bars to the roof and the floor. This setup can also be seen on trains. The intricate designs and the cross-cutting axes of the fittings are easily achievable through die casting. Old methods like sand casting will do, but it will take more time. Because the dies determine the shape of the final product, holes and threads can already be machined in just one processing. There is no need for post-machining.
Engine blocks, radiator cases and some gears are also die castings used for buses. These components are usually made from aluminum and magnesium alloys. They can also be a combination of several alloys to achieve specific hardness or stress-resistance.
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 aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Processing of Die Castings used for Airplane Parts
Processing of Die Castings used for Airplane Parts. Die Castings used for airplane parts are increasingly demanded for the aircraft industry. This type of constructions need light weight for mobility. Moreover, it requires durability and resistances to several stresses while flying. Among metals, aluminum is processed to serve as frames or skeleton of the aircraft.
In the process of die casting, molten metal is quickly forced into a mold cavity, which is formed by two opposing dies. Very high pressures are maintained until the metal solidifies. As for aircrafts, the strength of aluminum is significantly increased by high pressure casting. It creates yield of 69%. Aluminum die castings used for airplane parts are strong against torsion and expansion stresses. These are important considerations since a flying aircraft is subjected to several forces.
In this machining process, there is always an associated imperfection called porosity. This is the amount of gas that combines with the solidifying metal, as it cools in the mold. Porosity is characterized by the size and number of air bubbles inside the finished product. There are three levels of porosity. The second and third levels are unacceptable when it comes to machining airplane parts. This is to guarantee safety of the passengers. Advanced technology in treating aluminum is applied to minimize the porosity of the frames.
Die castings used for airplane parts are usually made of different aluminum grades. For example, Al 7075 is commonly used for making frames because of its toughness. Al 5052 can be die casted into billets, planes, coils, tubes and bars.
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 custom metal parts to their customer. If you would like more information about Kinetic Die Casting, please visit our website:Kinetic Die Casting Company
Metal Die Castings Used for Car Parts
Metal Die Castings Used for Car Parts. In the modern automotive industry, individual cart parts are required to be strong, durable and with a good finish. Hence, die castings used for car parts and accessories have been the standard for the industry. High pressure die casting is a metal-working process that can produce highly detailed parts. These are perfect both for internal parts for motors and transmission. Die castings have high yield strengths and tensile resistance too.
Basically, die casting is performed for automotive parts through a pair of dies. Molten metal is injected to the cavity between the dies. Then, a pressure between 10-175 MegaPascals is sustained until the metal solidifies. The product piece is uniform inside and out, with minimal porosity and external scrap. It has a yield of about 70%. Because of the speedy operation, the method is recommended for large scale productions.
Die castings used for car parts include sprockets, gears, fixtures and frames. Sprockets’ specifications are obtained almost perfectly after casting, resulting in smooth contact with the chain. There is no need for grinding or sanding. The method can also be used for small gears, but they are not suitable for high loads or rotating speeds.
Most frames and fixtures for automotive are die castings used for car parts. They are commonly shaped from Aluminum, a metal with high tensional strength. Because of aluminum’s high melting point, the recommended the process is cold chamber die casting. After casting, there are only few post-machining tasks to do. These involve cutting out of holes for assembly and screws.
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 Los Angeles die casting company that manufactures aluminum and zinc parts. If you would like more information, please visit our website:Kinetic Die Casting Company
Posted in Auto Parts
Tagged aluminum, Aluminum Auto Parts, aluminum parts, die casting, Die Casting Company, Diecasting Process
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