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/

Growing Impact of Aluminum Die Casting Parts in Various Industries

Die casting aluminum is mostly used in large manufacturing units. This process is very much acclaimed for its reliability and strength. Used in various industries they are cost effective in nature and immensely cater to the demand of users. Their advent can be seen more in aerospace industry where precision and quality is vital. Components made from casting aluminum are solid in nature and are resistant to harsh weather condition. Product crafted from aluminum is mostly used in aviation and commercial industries. Of immense potentiality these aluminum die casting products gel with other metals and offer flexibility by all means.

 

Aluminum die casting parts are comparatively better than plastic injection molded parts. Tag for quality, it bags excellence in all manufacturing endeavor. These aluminum parts are a natural shield for RF and EMI and prevent radio frequency. Stronger and stiffer casted aluminum parts are more stable dimensionally and are resistant to heat. With high degree of permanence these aluminum parts are with highest tolerance and finest finish. Ensuring more uniformity and dimension accuracy, aluminum die casting parts have drawn attention of the users. Its applicability in aircraft industry mark safety by all means. Light in weight and durable at high temperature these die casted products are of huge benefit to aviation industry which includes aircraft seats, components for the passenger cabin or baggage compartment etc.

 

This technology is marked for its high quality and utilitarian parts. Used in making electronic devices like cell phones and MP3 players, digital cameras and flat screen monitors and many others they also form an important part of construction industry. Aluminum casting is known for producing precision parts in high volume at low costs. While ensuring good surface finish they eliminate the need of post machining. Manufactured under strict supervision of experts, die casted aluminum parts ensure impeccability and comply with the international standard. Owing for superior attributes, these casted parts are commonly used in electrical, telecom, automobile and plastic industries. When it comes to strength and weight zinc casting parts offers best pact.

 

Aluminum die casting is used in number of industries because of its marked quality and excellent trait. Need of various industries this process lower cost and ensures productivity. As of you know how these aluminum die casting parts are useful, you can easily choose to avail them online. By browsing internet you can get handful suggestions and opt for the best that suits your need.

 

Champion H&C Inc. is an expert of Zinc, Aluminum, Magnesium Alloy tooling and mold design. We can provide superior quality aluminum die casting parts and various services to meet clients’ demands. If you need further information about our company, welcome to visit our website and send inquiry to Champion!

 

Article Source: http://EzineArticles.com/5856003

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

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What Do You Know About Gravity Die Casting?

With sand casting the mold is broken up after each casting operation, but with the process known as gravity die casting, the mold also called a ‘die’ is manufactured from metal, and can be used a large number of times. This means that the die is much more expensive to make, than an expendable ‘one use only’ mold. An intermediate technique makes use of semipermanent molds, which are made of gypsum plaster or fireclay, which can be used repeatedly for a limited number of castings. With gravity die castings, the most widely used materials for die-making are cast iron, steel, and heat resisting alloys of iron. For some specific purposes other materials are used to manufacture the dies, and these can include, aluminum, copper or graphite. A metal die can produce smooth castings with a clean surface, and a very high dimensional accuracy. Gravity die castings require very little or no final machining or other finishing treatment. The service life of metal dies can vary in terms of the number of castings it can produce, and this depends on certain factors such as the casting material, the thermal metal shock resistance of the die material, the temperature at which it is poured, and the casting method employed.

Many different details need to be taken into consideration when designing the pattern from which the die is made. For instance the pouring-gate system and risers need to be considered so that the walls of mold allow a quenching action upon the molten metal so it van solidify more rapidly than in sand casting. Also the die must be provided with channels at the joints and air vent holes to allow air from the hot metal to escape from the interior of the die. The die must also be constructed so it will not restrict the shrinkage that occurs, when the metal cools. Shrinkage can present difficulties when designing the cores which form the casting. Usually the cores are made from steel or special alloys, and sometimes compressible sand or shell cores are used.

To prevent the casting metal from sticking to the die, the die can be given an internal coating of chalk, clay, or bone ash with water glass as a binder. This mixture can be applied to the die by spraying, brushing or immersion.

With simple castings the molten metal may be poured in at the top. It should be designed to allow the molten metal to flow quickly without turbulence into all parts of the die. For metals with low melting points the die is sometimes heated to prevent premature solidification, and for metals with a high melting point, the die may have to be artificially cooled after each casting operation.

Slowly moving or tilting the die while casting can reduce turbulence and enable the metal to flow more smoothly, particularly when heavy castings are being produced. For awkwardly shaped castings, a vacuum may be applied to help the filling of the die. Slush casting, is a technique used for producing ornamental or hollow castings: the molten metal is poured into the die, and when a solid shell of sufficient thickness has formed, the remaining liquid is poured out.

Although die castings are cheaper than sand castings, the die tooling is more expensive, and an optimum number of castings need to be produced to make the process cost effective.

Article Source: http://EzineArticles.com/?expert=John_Cheesman

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Professional ductile iron provided by Cheng Feng Casting Factory

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 iron, 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 casting and ductile iron, Cheng Feng is you best choice. They can offer quality casting, best service and competitive price to their customers.

Not only Cheng Feng imports newest production equipments from Japan and America for top of the line products, but also they have participated Meehanite Foundry Association of Japan, to be under the supervision and guidance in foundry technology.

Furthermore, Cheng Feng sends their technicians regularly to Japan for training while they have also hired senior technician periodically from Japan to be as instructor at their plant.

 

*All iron casting products can be directly precision machined at Cheng Feng’s machining division, which will save time and money for their customers. This also makes it easier for the process management.

Pressure Die Casting – Magic Precision

Magic Precision Inc. is a pressure die casting manufacturer in Asia founded in 1998 and backed by a family that has 40 years of experience in the toys and power tools manufacturing business.We, Magic Precision is a high-tech company including casting china, die cast zinc, pressure die casting and casting foundry etc. We operate from the world’s largest manufacturing clusters—Taiwan and coastal regions of China—and your die cast products are delivered to you directly from our factories, providing the same low cost manufacturing services long enjoyed by high volume companies. We are dedicated to providing high quality die casting and related manufacturing services at competitive prices for low to medium sized orders.Our main goals are highly efficient manufacturing processes, speedy services, perfect inspection, and quality as top priority. Magic casting foundry manufactureris looking forward to cooperating with you!

pressure die casting

pressure die casting

No. 81, Lane 245, Section 3, Shatian Rd.
Dadu Township, Taichung County, Taiwan 43241
Phone:+886-4-2698-5000
Fax: +886-4-2698-5858
E-mail: info@mgprecision.com

 

Pressure Die Casting of Magic Precision Inc.

Magic Precision Inc. is a pressure die casting manufacturer in Asia founded in 1998 and backed by a family that has 40 years of experience in the toys and power tools manufacturing business. We are backed by a family with over 40 years of experience in the toys and power tools manufacturing business (owning two factories in China with 2,000+ workers). In addition, we offer contract manufacturing services for both secondary operations and light mechanical assemblies. Magic Precision Inc. is one of the best internationally known press die casting suppliers from Taiwan and China.If you are interested in our product lines, please always feel free to contact us without hesitation.

 

Magic Precision Inc. (Headquarters)
No. 81, Lane 245, Section 3, Shatian Rd.
Dadu Township, Taichung County, Taiwan 43241
TEL: +886-4-2698-5000
Fax: +886-4-2698-5858
E-mail: info@mgprecision.com