Die casting is the process of producing a large quantity of intricate and geometrically complex parts with unique designs through the use of a reusable mold created to the specific design of mass-produced components. The die casting process involves the use of a furnace, metal, die casting machine, and die.The metal for die casting, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace. Depending on the type of metal being cast, a hot- or cold-chamber machine is used. In essence, the die casting process works by pouring or injecting molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.The castings that are manufactured in the die casting process can vary greatly in weight and size, ranging from a couple of grams to a hundred kilograms.The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production.
Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
Die casting has been a specialty of Precise Cast for over 15 years. Our die casting services have been helping many mechanical engineers, product designers and architects make their designs to life with state of the art part designs and reliable quality. Provided complete system of production, quality management system and high-quality workforce, you are guaranteed quality manufacturing of your custom parts and products at highly efficient and economical method.
Die casting typically makes use of non-ferrous alloys. There are four most common alloys that are shown below, along with brief descriptions of their properties.
|Aluminum Alloys||Low density，Lightweight，Good corrosion resistance， High thermal and electrical conductivity，High dimensional stabilityfor very complex shapes and thin walls，Good mechanical properties，retains strength at high temperatures，Relatively easy to cast， Requires use of a cold chamber machine|
|Copper Alloys||High strength and toughness，strength approaching that of steel parts, High corrosion and wear resistance，Highest mechanical properties of alloys die cast,High dimensional stability Highest cost， Low die life due to high melting temperature，Requires use of a cold chamber machine|
|Magnesium Alloys||Very low density，Lightest alloy，High strength-to-weight ratio， Excellent machinability after casting，Use of both hot and cold chamber machines|
|Zinc alloys||Economical for small parts，High-density，High ductility，Good impact strength，Excellent surface smoothness allowing for painting or plating，Requires such coating due to susceptibility to corrosion，Easiest to cast，Can form very thin walls Long die life due to low melting point，Use of a hot chamber machine|
The selection of a material for die casting is based upon several factors including density, melting point, strength, corrosion resistance, and cost.If the ability to withstand high temperatures is your highest priority, you will want a mostly aluminum alloy in your die cast part. If a lightweight part is your highest priority, you will usually want to go with magnesium, which is extremely light. If ease of casting, economy and a great-looking final product are your top priorities, you may want to look more into zinc alloys, which cast very simply, still have good strength, hardness, and dimensional stability, and are quite easy on your dies, giving them a longer life than aluminum alloys have. If corrosion resistance, strength, and wear resistance are your main requirements, consider brass alloy which is another special alloy.
We manufacture low volume production to large precision die casting components in a broad range of aluminum alloys, zinc alloys, and magnesium alloys, using hot chamber and cold chamber die cast technologies, along with our proprietary automated die casting production line. Each of the alloys has unique physical characteristics to match your specific design and application. Our material experts will help you pick the ideal material to manufacture your precision die casting components.
Die casting fosters the attainment of Intricate and geometrically complex designs and forms, making it easy to customize the casting to specific manufacturing processes.
Die-casting technology enable parts to be manufactured at a much higher rate than other casting processes. Automatic die cast work cells are employed to increase production efficiency.Since die casting is made from die casting mold, they can be obtained within specified tolerance and shapes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required. So it’s quite easy to put on mass production. In general, a cold chamber die casting machine is die-casting 50 to 90 times per hour. The hot chamber die casting machine is die-casting 400 to 900 times per hour.
Die casting produces parts that are durable and dimensionally stable when maintaining close tolerance.The general tolerance class of die casting parts is IT13~IT15 in GB/T 1800-2009, and the higher precision can reach IT10~W 1 1. Surface finish (Ra) is 3.2~1.6μm, and locally up to 0.8μ Due to the high dimensional accuracy and high surface finish of die castings, less demanding die castings can be used directly, avoiding machining or less machining, improving the utilization of the alloy and saving a lot of machining costs.
Thin-wall die casting parts offer the highly valued combination of superior strength and lighter weight than those possible with other casting methods.Die castings can have complex part shapes, the wall thickness of the part can be smaller simultaneously, compared with sand castings and metal mold castings. The minimum wall thickness of aluminum alloy die-casting parts is 0.5mm. The minimum wall thickness of zinc alloy die castings can achieve 0.3mm. Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
Die-cast parts are typically less expensive than other metal alloys casting in the mass production stage.Since durable and dimensionally stable die casting parts can be obtained with specified shapes, so no machining or less machining is required.
Die casting parts can have many finishing techniques and surfaces. They can be created with smooth or textured surface finishes, meanwhile, they are also easily plated or finished with a minimum of surface treatment.
As a China-leading die casting manufacturer, Precise Cast offers you complete and thorough assembly for castings, as well as a full inspection of all die-cast parts and products. You’ll get a full-service experience in our die casting plant.
It’s common sense that quality is very important for die casting manufacturer and their customers. This is why we must take strict quality control during the die casting process.Precise Cast is a leading die casting manufacturer that puts quality control a high priority throughout each step of the casting process. It is kept in mind of all our staff that defect prevention is less expensive than defect detection in manufacturing, which allows us to pass our savings on to you!
Excellent accountability for product quality in every team member who participates in your customized die casting project.
Continuous performance improvements are measured by industry-wide metrics that drive our team to meet your quality standards.
An integrated organization that applies die-casting manufacturing automation and process controls at every stage of production for every industry served.
Maintains laboratory and measurement areas that are capable of effectively.
Managing product compliance to meet your specifications.
Consistently maintains strict density and porosity standards, process.
Monitoring and quality audits occur at every stage of the die casting process.
Monitors, tests, and analyzes each customized casting cycle to your exacting standards.
Participates in quality assurance and lean manufacturing training that demonstrates expertise in statistical process control procedures.
To ensure you the best quality control standards, you can have a complete review of all factors engaged in production, which includes:
In addition to our state-of-the-art automated die casting machinery and quality inspection facilities, our expert staff interfaces with the machines to fix detected problems and inspect the product for deficiencies.
Aluminum die casting services for compressor pistons, connecting rods, heat sinks, bearing housings, and many more specific parts.
Bath grips, cooker dials or kitchen cabinet door handles.
Aluminum die casting manufacturer for electrical housings, covering all the parts from LED modules to cell tower equipment.
Parts for rifles and shotguns, including aluminum die-cast trigger guards and receivers.
We’re a leading aluminum die casting company for ultrasound systems, drug dispensers, heart monitors, bed gearboxes, and more parts for medical devicessuch as zinc-based medical valves, medical gas outlets, and terminal unit.
We offer manufacturing for a diverse range of game tokens, golf ball markers, decorative badges, and other leisure industry products.
Parts developed through aluminum die casting for recreational vehicles, plus lawn and garden tractors.
Get small engine parts and accessory design and development from one of the most experienced aluminum die casting companies in China.
We specialize in truck parts and systems, such as cylinder heads, oil sump, clutch housing, steering box, engine support, intake manifolds, suspension arm, front and rear brake calipers.
As a die casting supplier in this very comprehensive industrial base, we are honored to have the opportunity to participate in a concerted way with being an integral part of our customer’s team that has enhanced as well as effectively supported their ability to attain or exceed the business goals and objectives they have set forth and achieved.