A masterful blend of detail and scale, die casting creates uniformly exquisite components across industries. Its hot and cold chamber techniques exemplify precision in mass production.
Discover the essence of this essential manufacturing art.
Let’s embark on a journey through the core mechanics of die casting, exploring its steps, suitability, and the subtleties of its machinery.
What is die-casting?
Spuitgieten is a metal casting process in which molten metal is subjected to high pressure within a mold.
The mold is usually made of a stronger alloy that is machined to create the desired shape. This process is similar to injection molding.
Die casting is suitable for the mass production of large quantities of products, especially for producing complex-shaped small to medium-sized castings.
Die castings typically have high surface flatness and dimensional consistency.
Detailed Steps of Die Casting
- Smeltend: The selected metal material is heated to a liquid state and maintained at an appropriate temperature.
- Injectie: Liquid metal is rapidly filled into the cavity of the mold under the action of high pressure through the injection system.
- Koeling: The metal solidifies and cools in the mold to form the final shape of the casting.
- Demolding: Na afkoeling, de mal gaat open, and the casting is removed.
- Nabewerking: The casting may require subsequent processing steps such as removing the pouring gate, polijsten, and heat treatment to meet the requirements of the final product.
Hot-chamber die casting vs cold-chamber die casting
Die casting machines are mainly divided into hot chamber die casting machines and cold chamber die casting machines.
Hot chamber die-cast machine
The hot chamber die casting machine is characterized by its press chamber integrated with the furnace, usually immersed in liquid metal.
Dankzij dit ontwerp kan het metaal rechtstreeks van de oven naar de perskamer gaan zonder extra toevoerprocessen.
Een spuitgietmachine met hete kamer is geschikt voor de productie van zinklegeringen, magnesium legering, en ander gietmateriaal met een laag smeltpunt.
Ze hebben doorgaans een hoge mate van productie-efficiëntie en automatisering,
maar omdat de drukkamer en de injectiepons zich al lange tijd in een omgeving met hoge temperaturen bevinden, de levensduur kan worden beïnvloed.
Cold chamber die-cast machine
De perskamer van de spuitgietmachine met koude kamer is gescheiden van de oven, en het metaal wordt uit de oven geschept en in de perskamer van de spuitgietmachine gegoten.
Dit type spuitgietmachine is geschikt voor de productie van gietstukken van materialen met een hoog smeltpunt, zoals aluminiumlegeringen, koperlegeringen, enz.
Cold chamber die-cast machines typically require higher injection pressure and energy, but they can provide better metal purity and longer mold life.
Cold chamber die-cast machines are more common in industrial production, especially in the production of aluminum alloy die-cast.
Each of the two types of die-cast machines has advantages and limitations, and choosing the right type of die-cast machine depends on the casting material required to be produced,
the production volume, and the specific process requirements.
What are the advantages and disadvantages of die-cast?
Advantages of Die Casting
- Hoge precisie en nauwkeurigheid: Die casting offers excellent dimensional accuracy and consistency, producing parts with tight tolerances.
Complex shapes and intricate details can be achieved without requiring additional machining. - Kosteneffectief voor grote productieruns: Once the die is made, the process is highly repeatable, waardoor het ideaal is voor massaproductie.
Large volumes of parts can be produced efficiently, lowering the per-unit cost. - Fast Production Cycle: Die casting has a rapid production cycle, with each casting process taking only seconds to minutes, allowing for high throughput.
- Gladde oppervlakteafwerking: Die-cast parts generally have a smooth surface finish, which reduces the need for secondary operations like polishing or machining.
- Hoge sterkte en duurzaamheid: The parts produced are dense and strong, as die casting results in parts with fewer internal defects and porosity.
The pressure involved in the process improves the mechanical properties of the material. - Versatile Materials: Die casting supports a variety of non-ferrous metals, inclusief aluminium, zink, magnesium, en koper,
allowing manufacturers to choose the best material for their specific application. - Minimale materiaalverspilling: Die casting is highly efficient, het produceren van zeer weinig materiaalafval vergeleken met processen zoals CNC-bewerking, waarbij tijdens het vormen veel materiaal wordt verwijderd.
- Complexe geometrieën: Dit proces maakt de productie van zeer complexe producten mogelijk, gedetailleerd, en dunwandige onderdelen die moeilijk te realiseren zouden zijn met andere productiemethoden.
Disadvantages of Die-Casting
- Hoge initiële gereedschapskosten: Een van de grootste nadelen zijn de hoge kosten voor het maken van de dobbelsteen. Dit maakt spuitgieten minder kosteneffectief voor kleine productieruns of prototypes.
- Beperkt tot non-ferrometalen: Spuitgieten is over het algemeen beperkt tot non-ferrometalen zoals aluminium, magnesium, en zink.
Ferrometalen, zoals staal of ijzer, zijn vanwege hun hoge smeltpunten niet geschikt voor dit proces. - Porositeit en holtes: Tijdens het injectieproces kan lucht of gas vast komen te zitten, wat leidt tot porositeit of kleine holtes in het onderdeel, wat de structuur kan verzwakken.
- Groottebeperkingen: The size of the part is restricted by the size of the die and the machine. Die casting is generally better suited for smaller to medium-sized components.
- Material Brittleness: Some die-cast materials may exhibit brittleness, which limits their ability to withstand heavy mechanical loads or harsh conditions compared to forged or machined parts.
- Secondary Operations May Be Required: Despite the high precision, some parts may require secondary finishing or machining to meet very tight tolerances or specific surface quality requirements.
- Not Ideal for Prototyping: Due to the high tooling cost and setup time, die casting is not suitable for prototyping or small production runs.
It’s best suited for mass production where economies of scale come into play. - Temperature Constraints: Die casting is limited to metals with lower melting points because the molds are typically made of steel. Extremely high-melting-point materials would damage the mold.
Considerations for die-casting materials
Manufacturers must consider certain factors and variables when choosing die-cast materials. Deze omvatten:
- Whether the material is suitable for hot-chamber die-cast
- Material costs
- Indirect materials costs (bijv. any extra post-processing required)
- Material structural properties
- Kracht
- Gewicht
- Oppervlakteafwerking
- Bewerkbaarheid
All of these factors should be considered when choosing a die-casting material for parts or prototypes.
The requirements for materials vary depending on the application, so the material selection must be based on specific usage conditions and performance requirements.
Classification and application of die-casting alloys
Die-casting alloys refer to various metal materials used in the die-cast proces, which can fill the mold cavity under high pressure and high speed, and form accurate castings after cooling and curing.
Die-cast alloys mainly include aluminum alloy, magnesium legering, zinc alloy, and copper alloy.
Each type of alloy has its own unique physical and chemical properties and is suitable for different industrial applications.
Aluminium legering die-cast
Aluminum die-cast alloys are favored in automotive, elektronica, and consumer goods for their low density, hoge thermische geleidbaarheid, kracht, en corrosiebestendigheid.
Their lightweight enhances fuel efficiency and cuts emissions, crucial for automotive applications.
These alloys offer a good surface finish and can form complex shapes, ideal for mass production.
- ADC12: This is an aluminum-magnesium alloy, with good fluidity, Hoge hardheid, strong corrosion resistance, and good processing properties.
It is suitable for the manufacture of various structural parts and body shells. - A384: This is a high-strength die-casting aluminum alloy, with high strength, stijfheid, and good heat resistance, suitable for manufacturing auto parts and mechanical structures.
- A413: This aluminum alloy has moderate strength, good plasticity, and strong corrosion resistance,
which is suitable for the automotive industry and the field of structural parts manufacturing. - AK5M2: This is a kind of high hardness, high strength die-cast aluminum alloy, with good wear resistance, suitable for automotive parts, aircraft and rail transit, en andere velden.
- YL113: This is a kind of high-strength die-cast aluminum alloy independently developed and produced in China,
met goede corrosieweerstand, slijtvastheid, en mechanische eigenschappen, suitable for aerospace, Automotive -motoren, en andere velden. - YL102 (ADC1) and YL104 (ADC3): These are aluminum-silicon alloys with good casting and mechanical properties, suitable for the manufacture of a wide range of die castings.
- YL112 (A380), YL113 (ADC10), and YL117 (ADC14): These are aluminum-silicon-copper alloys with high strength and good heat resistance, suitable for the manufacture of demanding die castings.
- ADC6: This is an aluminum-magnesium alloy, compared with ADC12, its corrosion resistance is better, but it is slightly inferior to ADC12 in die casting and machining performance.
Magnesium legering die-casting alloy
Magnesiumlegeringen, noted for low density and high strength, are optimal for structural lightweighting in automotive, ruimtevaart, en elektronica.
Their high specific strength and damping qualities suit dynamic load applications well.
Nog, they exhibit lower corrosion resistance and reduced mechanical properties at high temperatures, key considerations in material selection.
- AZ91D: This is a commonly used magnesium-aluminum alloy with medium strength, good casting properties, en corrosiebestendigheid.
AZ91D alloy is easy to process and is suitable for manufacturing various die-casting parts. - AM50A: This is a magnesium-silicon alloy that is known for its good ductility and high impact strength, making it suitable for die-cast parts that require a certain degree of resilience.
- 1AS71: This is a magnesium-zinc alloy with high strength and hardness while maintaining good casting properties, making it suitable for manufacturing high-strength die-cast parts.
- ZK60: This is a magnesium-zinc-copper alloy with very high strength and hardness, but relatively poor casting properties, making it suitable for manufacturing high-performance small die-cast parts.
- WE54: This is a magnesium-rare earth alloy with excellent high-temperature performance and anti-creep ability,
waardoor het geschikt is voor de productie van spuitgietonderdelen voor werkomgevingen met hoge temperaturen.
Zink legeringen spuitgieten
Zinklegeringen, met goede gieteigenschappen en hoge sterkte, geschikt voor de vervaardiging van decoratieve en functionele onderdelen. Koperlegeringen, bekend om zijn superieure elektrische en thermische geleidbaarheid, blink uit in elektrische en warmtewisselingstoepassingen. ty.
- LASTEN 2: Dit is een universele gegoten zinklegering met goede mechanische eigenschappen en oppervlakteafwerking, geschikt voor de vervaardiging van verschillende complexe vormen van onderdelen,
zoals auto-onderdelen, elektrische behuizingen, enz. - LASTEN 3: Als de meest gebruikte gegoten zinklegering, LASTEN 3 heeft uitstekende vloeibaarheid en corrosieweerstand,
die geschikt is voor de vervaardiging van veeleisende producten, zoals hardwareaccessoires, huishoudelijke artikelen, enz. - LASTEN 5: Vergeleken met ZAMAK 3, LASTEN 5 heeft een hogere sterkte en taaiheid, die geschikt is voor de vervaardiging van onderdelen die grotere belastingen vereisen,
zoals auto-onderdelen, construction machinery parts, enz. - ZA-8: ZA-8 is a high-quality die-cast zinc alloy with excellent surface treatment properties and dimensional stability, often used in the manufacture of precision parts and decorative products.
- AZ91D: This is an aluminum-containing zinc alloy that has good strength and heat resistance,
and is commonly used in the manufacturing of parts in the automotive and aerospace industries. - ZA-27: ZA-27 is a kind of high aluminum zinc-based alloy, which overcomes the low-temperature brittleness of some alloys, has high strength and elongation,
and is widely used in the manufacture of bearing bush, asmouwen, worm gear, enz.,
mainly used in mining machinery, cement machinery, and other heavy machinery equipment. - Za-8: ZA-8 is the only hot chamber zinc die-cast alloy in the ZA series, met een hogere treksterkte, hardheid, and creep properties,
suitable for manufacturing parts in the automotive and aerospace industries, especially those requiring high density, hoge sterkte, and high durability.
Design Considerations in Die Casting
Die-casting design involves a complex process encompassing material selection, schimmelontwerp, and optimization of process parameters.
Here are fundamental factors to consider during die-cast part design:
- Materiaaleigenschappen: Choose appropriate spuitgieten alloys based on required mechanical properties, corrosiebestendigheid, thermische geleidbaarheid, and electrical conductivity depending on the application.
- Vormontwerp: Mold design must ensure precise dimensions and quality surfaces for the cast pieces.
Consideration should include gating system layout, cooling system optimization, effective venting, and choice of parting lines. - Procesparameters: Temperatures, pressures, and speeds significantly impact the quality of the casting.
Determine optimal process parameters through experimentation and simulation analysis. - Structural Optimization: Optimize the design of die-cast components to minimize uneven wall thicknesses,
and internal defects such as porosity and shrinkage voids, en de algehele kracht verbeteren. - Kosteneffectiviteit: Factor in costs including material, mallen maken, and production efficiency during the design phase.
- Manufacturability: Ensure designs align with existing die-cast machine capabilities regarding clamping force, shot capacity, and cooling ability.
Latest Trends and Technologies in Design
- Precision Die Casting: To meet high-performance demands, precision die casting techniques produce highly accurate and smooth-surfaced castings.
- Computerondersteunde techniek (CAE): CAE technology’s role expands in identifying and solving potential issues early in the design stage, optimizing designs.
- Slimme productie: IoT sensors and data analytics monitor real-time casting processes and mold conditions, verbetering van de productiviteit en productkwaliteit.
- Lichtgewicht ontwerpen: Industrieën als de automobiel- en ruimtevaartsector streven naar lichtere gegoten componenten om het energieverbruik te verminderen en de brandstofefficiëntie te verbeteren.
- Duurzame materialen: Het groeiende milieubewustzijn stimuleert onderzoek naar recycleerbare of biologisch afbreekbare materialen binnen de spuitgietsector.
Key Points During Design
Bij het ontwerpen, houd de volgende punten in gedachten:
- Vermijd scherpe hoeken en complexe interne structuren: Dergelijke kenmerken kunnen matrijsslijtage versnellen en productiefouten introduceren.
Zorg voor voldoende diepgangshoeken: Vergemakkelijkt het eenvoudig verwijderen van gegoten onderdelen uit mallen.
- Denk aan krimppercentages: Houd rekening met krimp tijdens het afkoelen om inconsistenties in de afmetingen te voorkomen.
- Tolerantiespecificaties: Selecteer toleranties verstandig om compatibiliteit tussen gegoten componenten en andere samenstellingen te garanderen.
Conclusie
Die casting remains a critical manufacturing process that enables the mass production of high-quality, duurzaam, and complex metal parts.
Its precision, snelheid, and efficiency make it the go-to solution for industries requiring high-volume production with consistent quality.
As manufacturing technologies continue to evolve, die casting will likely maintain its status as a cornerstone of industrial production.
Whether you’re looking to create lightweight aerospace components or intricate electronic housings,
die casting provides the ideal combination of precision and mass production capabilities.
