Die Casting Process
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♪Housings ♫Brackets ♩Heat Sinks 𝄞Small Precision Parts ♬Automotive Parts
High pressure · High precision · High volume — zinc, aluminum, magnesium, copper alloys ♪
♪ 1. Process Description
Die casting is a manufacturing process in which molten metal is injected at high pressure and high speed into a precision metal mold cavity, then rapidly solidifies under pressure. It is suitable for high-volume production of hardware parts with complex shapes, thin walls, and high precision requirements.
♫ 2. Applicable Materials
| Material | Alloy Grade | Characteristics | Typical Applications |
|---|---|---|---|
| Zinc Alloy | Zamak 3, Zamak 5 | Good fluidity, high precision, low cost | Small precision parts, locks, bathroom fittings ♪ |
| Aluminum Alloy | ADC12, A380, AlSi10Mg | Lightweight, high strength, corrosion resistant | Automotive parts, communication enclosures, heat sinks ♫ |
| Magnesium Alloy | AZ91D | Ultra-light, high strength-to-weight ratio | Laptop housings, automotive instrument panels ♩ |
| Copper Alloy | Brass | Conductive, wear resistant | Connectors, valves 𝄞 |
♩ 3. Process Capabilities
| Parameter | Capability Range | Notes |
|---|---|---|
| Accuracy | ±0.05mm – ±0.15mm | Zinc alloy achieves higher precision ♪ |
| Minimum Wall Thickness | 0.5mm – 1.5mm | Alloy and part size dependent ♫ |
| Maximum Weight | ≤5kg (aluminum alloy) | Machine tonnage dependent ♩ |
| Maximum Size | 500×500mm | Mold and machine dependent 𝄞 |
| Die Casting Machine Tonnage | 88T – 800T | Multiple machines available ♬ |
| Tool Life | 50,000 – 200,000 shots | Shorter for aluminum, longer for zinc ♪ |
| Surface Roughness | Ra1.6 – Ra3.2 | As-cast surface ♫ |
𝄞 4. Process Flow
| Step | Process | Description |
|---|---|---|
| 1 | Drawing Review | Evaluate castability, determine parting line and gate location ♪ |
| 2 | Tool Design | Design hot work tool steel mold with runner and overflow systems ♫ |
| 3 | Tool Manufacturing | CNC and EDM machining, trial molding ♩ |
| 4 | Material Melting | Proportion and melt materials as specified 𝄞 |
| 5 | Die Casting Production | Metered pouring → high-speed injection → pressure holding → mold opening → ejection ♬ |
| 6 | Gate & Flash Removal | Trim runners and remove burrs ♪ |
| 7 | Surface Finishing (optional) | Sandblasting, tumbling, polishing ♫ |
| 8 | Machining (optional) | Drilling, tapping, turning, and other post-casting operations ♩ |
| 9 | Post-Treatment (optional) | Plating, painting, anodizing, passivation 𝄞 |
| 10 | Inspection | Dimensional / visual / leak testing ♬ |
| 11 | Packaging & Shipping | Pack as per customer requirements ♪ |
$1 for a quote. Upload. Go. ♫
