What is Aluminum Extrusion and The Benefits of Custom Aluminum Extrusion Fabrication

Aluminum extrusion is a process that shapes aluminum by forcing it through a die. It produces complex and lightweight parts that are strong and uniform. The parts are treated to improve their properties and can be customized to fit specific needs. Custom aluminum extrusion fabrication is a fast and cost-effective way to create high-quality components for various industries. It has many benefits, such as corrosion resistance, thermal and electrical conductivity, and aesthetic appeal. Custom aluminum extrusion fabrication is a key technology for modern manufacturing.

What is Aluminum Extrusion

Types of custom aluminum extrusions
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Aluminum extrusion is an industrial process that shapes aluminum by forcing it through a die with a specific cross-sectional profile. This method allows for the production of complex and lightweight components that are structurally strong and consistent in shape. The extrusion process begins with the selection of the appropriate aluminum alloy, such as 6061 or 7075, which is then heated and pushed through the die. The extruded material is cooled, hardened, and subjected to various treatments like T5 or T6 to achieve the desired mechanical properties. This process is ideal for creating a wide range of products, from simple angles and channels to intricate custom profiles.

Customization and Precision in Aluminum Extrusion Fabrication

Custom aluminum extrusion fabrication stands out for its ability to produce tailor-made solutions for specific industry needs. By designing a unique die, manufacturers can create profiles that perfectly match the requirements of their applications. The advanced technology involved in the extrusion process, including 3-axis and 5-axis milling machines, ensures high precision and quality. The material’s thickness, dimensions, and component weight can be controlled with tight tolerances, resulting in parts that meet the most demanding specifications. This level of customization and precision is invaluable for industries ranging from automotive to construction, where specialized components are essential.

The Benefits of Custom Aluminum Extrusion Fabrication

The benefits of custom aluminum extrusion fabrication are numerous and impactful. This process allows for on-demand delivery of extrusion parts, facilitating cost-effective series production. The use of aluminum in extrusion offers a lightweight yet durable solution, with the added advantage of being corrosion-resistant. Custom extrusions can also be designed to optimize thermal and electrical conductivity, making them suitable for applications such as electrical systems and cooling devices. Furthermore, surface treatments like anodizing and powder coating enhance the appearance and longevity of the components. With its combination of efficiency, versatility, and quality, custom aluminum extrusion fabrication is a cornerstone in modern manufacturing.


Precision Aluminum Extrusion by DMS Group

DMS Group is a leading provider of aluminum extrusion services, offering customization options using different aluminum alloys like 6061 and 7075. They can handle a wide range of material thicknesses and component weights, catering to both complex and large-scale extrusion needs.

DMS utilizes cutting-edge extrusion methods to ensure high accuracy and quality in the production process. They also provide various surface treatments like anodizing and powder coating to enhance the performance and appearance of components.

DMS Group is dedicated to delivering extrusions that meet the highest quality standards and adhere to your delivery schedule. Their service is tailored to your exact specifications, from design to the final product. They employ the latest extrusion technology and work with different aluminum series to create lightweight and durable parts.

With a commitment to precision, DMS Group guarantees tolerances up to 0.1 mm. They also offer heat treatment options like T4, T5, and T6 to optimize material properties for specific applications. Their goal is to provide flawlessly crafted solutions that are delivered on time to support your project.

Visit and find out more : https://www.dmsgroup-tw.com/

The Aluminum Die Casting Process and The Growth of Die Casting Industry

The casting process implements a steel mold often capable of producing tens of thousands of castings in rapid succession. The die must be made in at least two sections to permit removal of castings. The casting cycle begins with the two die halves are clamped tightly together by the die casting press. Molten aluminum is injected into the die cavity where it solidifies quickly. These sections are mounted securely in a machine and are arranged so that one is stationary while the other is moveable. The die halves are drawn apart and the casting is ejected.

 

Die casting dies can be simple or complex, having moveable slides, cores, or other sections depending on the complexity of the casting. Most machines use mechanisms actuated by hydraulic cylinders to achieve locking. Others use direct acting hydraulic pressure. Die casting machines, large or small, very fundamentally only in the method used to inject molten metal into the die.

 

What Are The Advantages Of Aluminum Die Casting?

There are many reasons aluminum is the most commonly cast non-ferrous metal in the world. As a lightweight metal, the most popular reason for utilizing aluminum die casting is that it creates very lightweight parts without sacrificing strength. Aluminum die casting parts also have more surface finishing options and can withstand higher operating temperatures than other non-ferrous materials.

 

Aluminum die cast parts are corrosion resistant, highly conductive, have a good stiffness and strength-to-weight ratio. The aluminum die casting process is based on rapid production that allows a high volume of die casting parts to be produced very quickly and more cost-effectively than alternative casting processes. Aluminum die casting has become the favored option for buyers worldwide. Characteristics and Advantages of Aluminum Die Castings include:

 

  • Lightweight and Durable
  • Good Strength-to-Weight Ratio
  • Great Resistance to Corrosion
  • Excellent Electrical Conductivity
  • Fully Recyclable and Reusable in Production

 

Aluminum Die Casting Product Segmentation

The popularity of aluminum has expanded to many applications around the world today, driving competitive market shares primarily for its distinctive features such as lightweight; corrosion resistance, high electrical and thermal conductivity, high stability for complex shapes and high tensile strength. The transportation sector is the largest end-use segment for this industry. The increasing emission laws by the government regulatory authorities, along with consumer demand for a higher fuel-efficient vehicle is developing a necessity for aluminum casting. An example of increased operations for the industry includes the replacement of iron and steel components in a vehicle with lightweight high-quality aluminum in order to increase the fuel efficiency. The aluminum die casting product is ideal for electronic connectors and housings die to its excellent electrical performance and shielding properties, even in high-temperature environments.

 

Another sector regarding the aluminum die casting demand includes building and construction in developing economies particularly in the Asia Pacific region. Aluminum Die Casting is associated with the creation of products including windows, cladding, curtain walling, prefabricated buildings, shop partitions, and fittings. Also, aluminum die casting products are used in aerospace operations or airplanes all around the world. The aerospace industry wants to produce a denser and larger quality product at lower costs for these air-frame components as aircraft continue to grow in size along with population rates.

 

According to Transparency Market Research, the Asia Pacific region accounts for over the half the share in the global market for aluminum castings. In the years ahead, the region is expected to further increase its share by pulling in the maximum Compound Annual Growth Rate of 5.3% during the forecast period between 2017 and 2025, and the powerhouse of China taking most of the credit. This market region is expected to become US $22.67 bn by 2025. Another important driving force includes the regions of Europe and North America in the global market for aluminum castings. While Europe is expected to register a Compound Annual Growth Rate of 5.1% during the forecast period to become worth US $9.45 bn, and the North America regions is expected to rise at a Compound Annual Growth Rate of 4.9% to become worth US $4.22 bn by the end of the year 2025. The statistics provided in this article express the importance in future Aluminum Die Casting growth for global production needs.

 

If you have requirement of aluminum die casting parts, I recommend you to visit Champion H&C Inc. – they are the professional aluminium die casting manufacturer in Taiwan. With years of experience, they can provide and custom best-quality die casting products for customers. Now, contact with Champion H&C to get more information of die casting services!

 

Article Source: https://www.phbcorp.com/what-is-aluminum-die-casting/

The Best Casting Process for Your Needs

In the field of metal work, various methods of casting are used to turn molten metals into specific shapes for use in commercial and industrial products. Within each casting process, a cavity is formed in which molten metal is poured either with gravity or high pressure. After a number of seconds have passed, the metal solidifies and the newly hardened casting is released from the mold or form.

 

Casting is most often employed to make intricate metal objects that would otherwise be complicated and much costlier to produce with different methods.

 

The process of casting has existed since ancient times. Some of the earliest examples of metal casting exist today in the form of jewelry, tools and sculptures that have been retrieved from archeological sites and put on display in museums around the world. Early methods of casting included plaster mold casting and lost wax casting.

 

Today, the methods of casting fall into the non-expendable and expendable categories. Other variants of the two categories include the methods used to fill cavities — including pressure and gravity — and the material used to form a particular mold.

 

First, there’s the non-expendable type of casting, which would account for any method in which the mold can be used again. Examples of non-expendable casting include permanent mold and die casting methods, in which the molding cavities are made of metal. Non-expendable casting is often favored for its ability to produce uniform parts at high volumes.

 

Expendable casting accounts for any method in which the mold is discarded after a single use. Examples in this category include sand and plaster casting, in which molten metal is poured into a cavity that is then broken away to reveal a finished casting. A further example of expendable casting is investment casting, a modern version of lost wax casting, in which molds are formed around wax patterns, which are then melted away to reveal hard ceramic cavities for subsequent metal molding.

 

Aluminum Die Casting

With aluminum die casting, a process takes place where molten metal is forced into a cavity in which a mold is formed. The process is achieved with a pair of steel dies that have been machined into particular shapes, which form the molding cavity when joined together. A similar process can also be applied with castings made of copper, magnesium and other metals.

 

The aluminum die casting process is divided into four stages: preparation, fill, ejection and trim off the gate.

 

First, a lubricant or die release agent is applied to each half of the cavity in preparation for the injection of the metal to be cast. Next, the dies are brought together and the cavity — in some cases one, in some cases two or more — is filled with molten metal under high pressure, which is maintained until the casting hardens.

 

A waiting period follows, after which the metal will have hardened into its final shape. With that step completed, the dies are separated and the castings are pushed out of the mold with ejector pins. Afterward, the parts that comprise the scrap — runners, sprues, overflows etc. — are trimmed away. In some cases, the finished shape will then receive sanding or polishing along the surfaces.

 

The high pressure at which the cavity is filled is crucial to the process because this prevents any part of the casting from hardening prematurely. This also ensures that the entire cavity is filled with no discontinuity, which could otherwise occur in die castings with complex shape formations. High pressure also eliminates the possibility of air bubbles, while the entrapment of air is further avoided with vents along the dies surfaces.

 

Aluminum die castings can also be produced with secondary features on molds, such as holes and grooves. Aluminum die casting is used to create everything from marine and sporting components to oil pumps, engine cradles, transmission transfer cases, heatsinks, enclosures, and brake components. The process is generally reserved for high-volume industrial productions.

 

Sand Casting

In the process known as sand casting, hardened casts of sand are used within a gating system to mold metals and other materials into shape. The sand is formed around patterns, which form cavities within the sand that are subsequently filled with molten metal. Due to sand’s heat-resistant quality, sand casting accounts for the vast majority of metal mold production.

 

To make the sand castings, sand is mixed with clay, water and sometimes other substances. The process here is a lot different than die casting because the hard sand that forms the mold is broken away and dispensed with afterward. Nonetheless, sand castings are often used to produce complex molds that are harder to make with die castings.

 

The process of sand casting is divided into several steps. First, a pattern is placed into the sand, where a cavity is then formed within the sand through the application of gating, after which the pattern is removed. In some cases, the cavity will be rather complex, with multiple grooves and several turns, twists and corridors.

 

Next, the cavity within the sand is filled at high pressure with molten metal. Once the metal has cooled into a hardened shape, the sand cast is broken away and the mold is removed. The finished mold might then be modified in whichever way is necessary, whether it needs to be trimmed or buffered to a smooth shine.

 

Sand casting molds are commonly used to make complex metal objects, such as one-piece equipment parts with various contours that would be hard to produce through other casting methods. Examples include the trap pipes used in household plumbing systems and metal doorknobs and lampshades.

 

Sand casting is also used for artistic items such as living room fixtures and metal sculptures. Sand casts are even used in jewelry production for items such as rings and metal bracelets. Whether the finished product is complex or simple, sand casting is a reliable method that allows manufacturers to form exact shapes with the utmost precision and detail.

 

V-Casting

An alternate form of sand casting is known as vacuum molding, or V-casting, which involves the use of unbonded sand. V-casting is often employed in the production of ferrous and non-ferrous metal molds.

 

The process makes it possible to form molds without the use of pressurized compaction methods, such as squeezing and blowing. Instead, clean molds are achieved with dry sand and vacuum pressure. V-casting allows manufacturers to do away with sand mixers and other equipment required for hardened sand.

 

V-casting can be carried out with a simple arsenal that consists of a vacuum system, a pattern, a film heater, a flask and a vibration surface. The process is generally clean and free of fumes or odors. Once finished, the dry sand is simply recycled for the next application. As such, V-casting is one of the most waste-free methods by which molds are cast for metal products.

 

In V-casting, patterns are placed onto boards with vacuum chamber vents. Heat-softened sheets of plastic are then placed over the pattern and the vacuums are activated. This causes the plastic to wrap tightly to the details of the pattern. Once hardened, the pattern is removed from the mold. Then, a vacuum process is utilized to pull molten aluminum through the cavities.

 

V-casting is often favored due to its ability to produce fine finishes with precise dimensions. A multitude of shapes can be achieved with the method, whether the mold is lightweight or heavy. The process allows you to reuse patterns multiple times and leaves little scrap excess material upon completion.

 

Investment Casting

Investment casting is a modern-day method of lost wax casting, which has been used for thousands of years in the creation of art fixtures, figures and masks. Archeological finds throughout Eurasia have included plates, vases and furnishings made with earlier forms of the wax casting method.

 

Investment casting is favored in a variety of industrial productions because of its versatility and accuracy of detail. Numerous mechanical pieces, such as valves and turbines, are made from the process of investment casting.

 

First, a master pattern is made from wax, or sometimes from wax replicas of a preexisting non-wax pattern. Next, a mold is created, which is also referred to as the “master die.” Several different wax patterns can be combined into a bigger pattern for a single molding. For industrial applications, the wax patterns are applied to a sprue that connects to a mechanical arm.

 

Next, the wax molds are dipped in ceramic with factory machinery. Then, the mold is heated and the wax melts out from the surrounding ceramic mold. With the ceramic molds now empty, molten metals are poured into the cavities formed by the ceramic.

 

Once the metal inside the ceramic molds have hardened, the ceramic forms are broken away. Afterward, excess parts are removed from the metal shapes, which are then readied for their ultimate use.

 

Where to Find Die Casting Manufacturer?

Champion H&C Inc. is a professional manufacturer of specializing in kinds of die casting processes and CNC machined products. Such as aluminum die casting parts, zinc alloy die casting parts, CNC lathe machining parts, CNC turning parts, and much more products that you all can find on Champion H&C website. If you need more information about die casting process, please do not hesitate to send inquiry to contact with Champion H&C Inc. immediately.

 

 

Article Source: https://diecasting.com/blog/2017/07/31/best-casting-process-for-your-needs/

Die Casting Parts Around Your Lives – Learn What Die Casting is.

Die casting is an important manufacturing technology used in many industries. Companies can make nearly all parts using different casting processes.

 

What is Die Casting?

 

According to The Engineer’s Handbook, this is a manufacturing process where solid metals are melted and heated to a desired temperature after which, it is poured into a cavity or mold with proper shape.

 

The melting and heating process may require different furnace heating temperatures. Moreover, different chemical substances may be added to modify chemical composition of metals.

 

The process may be a single step of a series steps depending on the complexity of the metal substance. Cast parts may range from fraction of inches to over 35 feet. And final product can have virtually any size depending on what designer desires.

 

Apart from these, it is also crucial to highlight the major metal casting processes that have been used in this industry.

 

  • Sand casting
  • Lost Wax casting
  • Permanent mold casting
  • Centrifugal casting

 

What Makes Die Casting a Distinct and More Importantly Intriguing?

 

All the other processes I have listed above are collectively referred to as “foundry processes” except die casting.

 

Let’s zero into what die casting is.

 

The Engineering.com defines die casting as a manufacturing process that produces metal parts of virtually all designs by forcing molten metal under high pressure into a die cavity. The underlying factor here is exerting high pressure through a die.

 

It is a key factor that distinguishes this metal fabrication process from the other metal casting procedures listed above.

 

For instance, if we look at a process such as lost wax casting, investment casting or sand casting procedures, the underlying factor in this case is the fact that, the process depends on gravity to fill the mold.

 

The Cambridge Dictionary defines gravity as a natural force that attracts objects towards one another, more so that force, which makes things fall on the ground.

 

This further reveals more properties of die casting in relation to other metal casting processes.

 

Here are three key points to note:

  1. Metal die casting process has a short cycle time
  2. Metal flow is faster in die casting due to existence of external force
  3. Molds in die casting are not as thick as those used in the sand casting or investment casting processes

 

Metal die casting process is used to produce various shapes from a number of non-ferrous metals such as brass, zinc, aluminum, magnesium and copper among other metals.

 

It is one of those manufacturing processes with the ability to produce high detailed and accurate parts. It is also preferred for mass production of components as opposed to other manufacturing processes. Take for instance, the faucet parts, door knobs, decorative parts, etc.

 

Die Casting Examples

Die casting is one kind of technology that we have lived to embrace in our day-to-day activities. This is a popular manufacturing process that is used to produce a number of metal parts both for industrial and domestic applications.

 

For this particular section, we’ll categorize these parts based on where they are used i.e. their industrial or domestic applications.

 

The most common die casting examples include the following:

 

Brass Die Casting Parts

These are common examples of die cast parts that we meet in our daily lives. They are available in different configurations. These lamp parts include brass fixture body parts, necks and breaks among others.

 

Most lighting distributors place their orders to different lighting parts suppliers, and give the brass lamp parts order to a casting manufacturer; this will save them a lot on cost.

 

Brass Parts May Include:

  • Brass electrical components such as the socket termination parts and coaxial cables.
  • Mechanical parts such as those that are used in the plumbing industry. These may include pipe joints, washers, nuts, flanges and T-joints just to mention a few.
  • House accents such as brass candle holders, vases, canisters, decorative pillows, etc.
  • Furniture hardware such as door knobs, locks, and handles.
  • Brass precision components such as clips, connectors and taps among other sections.

 

Zinc Die Casting Parts

Zinc is also a popular metal that is used in this industry. Normally, the manufacturers have to choose between the ZA and ZAMAK alloy. The choice of any alloy will depend on the desired physical properties of the end product. That is, parts cast using the ZA alloys have superior strength due to high mounts of aluminum. The Zamak alloys offer better castability.

 

The zinc die casting parts may include window hardware, electrical components, bathroom fixtures and office equipment, just to mention a few.

 

Steel Die Casting Parts

Like the other metals mentioned above, the steel cast parts also form an integral role of our lives. This involves casting different types of steels such as stainless steel.

 

Some of the most common components that are manufactured via this technique include valves, hydroelectric turbine wheels, tooling equipment and pumps among other parts in food, electrical and power industries.

 

All these parts must be manufactured as per the international standards and regulations.

 

Iron Die Casting Parts

This involves casting a number of iron carbon alloys. These metals have a carbon content that is more than 2%.

 

Again, the iron casting company should be able to choose that specific metal that can meet the requirements of the end users. This involves determining the carbon content, iron and silicon content.

 

Aluminum Die Casting Parts

Both aluminum and aluminum alloys are commonly used to cast different machine components. These alloys contain different elements such as copper, manganese, magnesium, silicon and zinc, just to mention few. These elements exist in different proportions thus; different procedures can be used to cast the aluminum parts.

 

These aluminum die casting parts are used in different industries such as aerospace, electronics, plumbing and chemical industries.

 

Summary

In summary, there are very many types of components and structured that can be manufactured through die casting. It is upon the end user to choose that kind of metal he/she desired for a given application. However, some may require additional secondary operations.

 

If you need further details about die casting, I recommend that you can visit the website of Champion H&C Inc.

 

This company provides various die casting processes for you. Such as aluminum die casting, zinc alloy die casting, etc. Moreover, they also give you CNC lathe machining, CNC turning, CNC milling services. Learn more information, please check Champion H&C website: www.hc-aluminum.com

 

 

Article Source: http://www.gatonbrass.com/die-casting/

Aluminum Die Casting – A Closer Look at Its Finer Nuances

The introduction of aluminum die casting goes back to 1914, when aluminum was invented for the first time. Though die casting was developed way back in the 1800s, yet only alloys of various compositions of tin and lead were used. However, aluminum revolutionized the whole concept of this amazing process.

 

Aluminum is Ideal for Die Casting:

 

The reason for the growing popularity of aluminum in die casting aluminum industry is for its lightweight and anti-corrosion properties. Apart from that, this metal possesses high dimensional stability for complex shapes and thin walls. High thermal and electrical conductivity, as well as ability to withstand high temperatures have made aluminum die casting a much-preferred option these days.

 

Cold Chamber Machines and Aluminum Die Casting:

 

Usually cold chamber machines are used for die casting aluminum, aluminum come with high melting points. The process involves pouring molten metal into a ‘cold chamber,’ or cylindrical sleeve. This can be done either manually by a hand ladle or by an automatic ladle. The next step involves sealing the cold chamber port and forcing metal into the locked die at high pressures with the help of a hydraulically operated plunger.

 

Automated machines in Die Casting:

 

Die casting aluminum these days have improved a lot and manual operations have rightly replaced automated quality control. Today there are many different types of machines utilized in die casting method, which can make your work easy, save your time and increase your productivity. While some die-casters use different tools to lubricate dies, ladle metal into cold chamber machines others use them to integrate other functions like quenching and trimming castings.

 

Even for adjusting Casting machines and assuring steady castings there are microprocessors these days. You can obtain metal velocity, shot rod position, hydraulic pressure and other data through these machines. Finally, all these helps in proper statistical analysis in quality control.

 

Proper designing for quality Die Casting:

 

Apart from using automated machines, for getting the right Aluminum Die Casting products it is necessary to have a great team of designers who take proper care to collaborate with casting experts. This is an essential prerogative during the early stages of designing in order to get a quality final product eventually. This also helps in cutting down unnecessary expenditures during the tooling and the production phase in Aluminum Casting. Designing and proper planning always results in proper execution, which in turn provides products that are of quality and have longer shelf life. This applies to Zinc Casting as well.

 

Champion H&C Inc. is an expert in Zinc, Aluminum, Magnesium Alloy tooling and mold design and manufacture. We provide professional skill suggestion in Mold design to our customer that can reduce risk and save more time in trial mold step, special in save cost. Our service is in Precise tooling design, tooling manufacture, Accurate test tool and Fixture, which will be requested by Optical Insulation, Electric, Computer Parts, RF, IA products, Optic, Varies Connector and Industrial Component.

 

Article Source: http://EzineArticles.com/expert/Alyna_Watson/478325

Article Source: http://EzineArticles.com/5650332

 

Iron Casting, Ductile Iron Manufacturer – Cheng Feng

Cheng Feng Casting Factory Co., Ltd. is a professional ductile iron casting company with main product of castings for machinery industry, such as casting iron, ductile irons, gray iron casting, ductile iron casting, small iron casting products, large machine casting parts and more.

 

For more than thirty years, Cheng Feng has dedicated in upgrading of foundry technology to their casting iron and ductile iron products. Pursuing new frontier has long been Cheng Feng’s company policy. They commit to improve product quality and meet the clients’ strict requirement.

 

Cheng Feng Casting offers all kind of castings services with high quality, best design and competitive price. OEM/ODM orders are accepted. Please contact us for more ductile iron casting products information.

 

“Quality Comes First” is not slogan. It is what makes up Cheng Feng’s competing edge in today’s turbulent competition. Looking for the reliance manufacturer of iron castings and ductile irons, Cheng Feng is you best choice. They can offer quality casting, best service and competitive price to their customers. For further casting information, please contact soon!

K Technologies: The Best Rf Module Manufacturer

K is one of the leading professional RF module in the world and specialized in researching and developing in field of RF modules with many years experience, for the domestic and oversea markets. We are proud to be a premier source for receiver modules, RF transmitter module, 2.4 GHz RF modules, 5.8GHz RF modules, wireless RF module, digital RF modules,and etc. We are constantly dedicated in developing and designing innovative products. We also insist and emphasis on the principles of service, quality, innovation and business continuity and keep optimum status to provide the best service and products to our customer. If you are interested in any of our series, please feel free to contact us for details.

 

Rf module

Rf module