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October 20, 2022

The Basics of Cold Chamber Die Castings in 2022

The Basics of Cold Chamber Die Castings
Cold chamber die castings are a process of die casting that use, instead of a hot chamber, a cold one. When starting the process, the molten metal is taken from the crucible and then inserted into a shot sleeve. Afterwards, a hydraulically operated plunger pushes the molten metal into the die. In order to minimize the shrinkage that usually occurs during silicification, as many material as possible is forced into the die cavity. Injection pressures usually have to reach over 10,000 psy or 70,000 KPa in order for the machine to function the way it should.
Cold chamber die castings are usually needed when the alloy is not eligible for use in hot-chamber machines for a variety of reasons. Such metals that require the cold chamber include aluminum, copper, zinc and magnesium alloys. Beforehand, the materials must be melted using a furnace. The problem with using cold chamber die castings is that the cycle time is a lot slower, since the molten metal needs to be transferred to the cold-chamber machine from the furnace.
When die casting, the dies needed are made out of steel because typical cast iron cannot take high pressures. This can serve as another setback to using the cold chamber, for the dies end up being very expensive, since steel is a costly metal. The dies can contain multiply cavities, or just one mold cavity, and there must be two dies – one for separation, and one for ejection of the final product. Many kinds of cold chamber machines are available with various features, but all of them function at maximum efficiency.

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September 29, 2022

The Importance of Aluminum Parts Type in 2022

Filed under: Aluminum Casting Parts — Tags: Cast Parts, Casting Aluminum, Die Casting Parts, Die Casting Process — admin @ 12:00 pm

The Importance of Aluminum Parts Types
Aluminum is a popular material for metalworking, and an even more popular metal when it comes to die casting. In fact, the sheer popularity of aluminum being used in the die casting process is so great that many companies have dedicated their services to producing aluminum parts types alone. Not only do companies focus on just creating them, for the parts need to be powder coated, or plated, pressure tested, tooled, mold altered, machined or casted. There are many types of aluminium casting, whether die, sand, plaster or permanent mold casting. Because of the wide variety of aluminum parts types, makers must take into account the shape, dimension, the complexity, mechanical properties, quality, surface finish and many other design features.
The reason for aluminum’s good reputation lies in its properties. Not only is it an efficient metal by being malleable, conductive to heat and electricity, ductile, strong and non-corrosive, it is, first and foremost, cheap enough to mass-produce and sell to the public. Many industrial applications thus involve aluminum and consider it the best metal around. A large number of aluminum parts types are being sold, acting as die cast parts for all sorts of machines, engines, rocket mechanisms, electronic gadgets and more. It is also used in daily products such as computers and various toys. Even kitchen utensils make use of aluminum, such as pots, pans and even skillets. Anything that uses high wire electricity makes use of aluminum as it is a good conductor of electricity. Aluminum is widely available all over the earth and it is thanks to that metal that many technological advancements have been made possible today.

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September 22, 2022

The Basics of Die Casting in 2022

Filed under: Aluminum Casting Parts — Tags: Cast Parts, Casting Aluminum, Die Casting Jobs, Die Casting Parts, Die Casting Process — admin @ 12:00 pm

The Basics of Die Casting

Die-casting is a process where the metal is placed under high pressure to be molded and turned into reusable steel. The molten metals are durable because of the process that they have undergone. The metals produced can be seen in commercial, consumer, and industrial products. They can be simple but others are complex like connectors. They can be seen mostly in automobiles, house equipment, toys, and office equipment. The usual alloys used in die-casting are zinc, aluminum, magnesium, copper, lead, and tin.
There are many advantages of die-casting. Economically speaking, it is efficient compared to other manufacturing processes. The parts produced have long life. The process is also high-speed and can mass-produce the parts even the complex ones. This is because of the molds or the dies used to produce the parts. Also, because of the molds, the parts are accurate and dimensionally stable. The accuracy and stability of the parts make them very durable and heat resistant. The strength and stability of the parts are due to the absence of fasteners or connectors within the parts because they are produced as one. The parts can also have different finishing from smooth to textured. Another advantage is that it can produce thinner walls as compared to other casting methods like sand casting and permanent casting.
The two methods in die-casting are hot chamber and cold chamber. The difference between the two methods is the type of alloys that can be processed in the machines. Hot chamber can process alloys with low melting point while the cold chamber can process alloys with high melting point.

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September 15, 2022

The Four Steps of the Die Casting Process in 2022

Filed under: Die Casting Tooling — Tags: Cast Parts, Die Casting Machines, Die Casting Molds, Die Casting Parts, Die Casting Process — admin @ 12:00 pm

The Four Steps of the Die Casting Process
The die casting process is a hard task, though in the end, it can be very rewarding. Basically, it is the process of subjecting a molten metal to high pressure in order to create mold cavities. These mold cavities are eventually transformed into dies. Die casting can only be done with metals, the most popular kinds being tin, lead, magnesium, copper, zinc, aluminium, and their alloys. Non-ferrous metals are the recommended kinds for die casting. As a whole, die casting is usually done when small or medium-sized metal parts are needed, and require good detail, dimensional consistency and a very fine surface quality. In the metalworking industry, the die casting process is immensely popular mainly because of its versatility.
One thing that die casting has to compete with, however, is the process of injection-molding plastic parts. People who would rather settle for cheaper things of lower quality are now turning to plastic instead of metal. However, when it comes to house parts and similar materials, die casting remains as the leading practice for small structures.
The die casting process can be summarized in four major steps. First of all, the mold needs to be sprayed with an amount of lubricant and then closed, for the lubricant will help control the die’s temperature, as well as assist in removing the casting. Then, the molten metal is put into the die under a very high pressure. The pressure must be maintained until the casting is solidified. After opening the die, the shot, using ejector pins, is removed, and then the scrap is separated from the castings.

September 8, 2022

Different Forms of Die Casting Tooling in 2022

Filed under: Die Casting Tooling — Tags: Cast Parts, Die Casting Company, Die Casting Parts, Die Casting Process, Die Casting Tooling — admin @ 12:00 pm

Different Forms of Die Casting Tooling

Die casting tooling can also be called insert die, die casting molds, or die casting dies. They can come in various forms, styles, and sizes. One of the forms of die casting tooling is the die cast tooling inserts. They are the least expensive among the tooling that requires heat-treating so that the life of the insert will be extended. The tooling life is the number of parts possible to be made in the inserts. The other form is the Prototype die casting tooling insert. They are the same with the first form of tooling but the only difference is that this type need not be heat-treated and can be damaged easily.
The next type is die casting unit die tooling and this is smaller than the complete mold but larger than the inserts. It also uses more steel compared to the inserts and less steel than the complete mold.
Complete Class A die casting die fits into the die casting machine without the use of any base or holder. This type produces better quality parts and more die life. It has waterlines and trim dies that can speed up the production.
Die casting Family Mold tooling has many cavity die inserts that can process single or multiple parts each cycle. It should be removed from the machine when changing inserts so it is costly and not time efficient.
Trim dies can save time in production and cut the excess alloy in the parts produced. They are mounted into a trim press and are pressed together with tons of pressure.

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