Die Casting Services and Products for a Wide Range of Industries

by Ryan Brown Custom Metal Casting Manufacturer

The die casting process is used in many of the consumers products we use in our daily lives, such as golf clubs, faucets, mobile phones, doorknobs, razor handles, power tools, eyeglass frames, and football cleats.

Referring to a manufacturing technique that allows for the mass production of metal parts in die casting factory by using high pressure to force molten metal into reusable die cavities, Die casting is a term used to explain the finished part.

Today, cleaner and more efficient machines, better material science advances in technology and improved manufacturing processes have combined to make die casting more of an exact science. In addition, cutting-edge software and better die design enable faster die fabrication, less waste, and enhanced performance.

All of this, along with continuous computerized automation and process-monitoring has reduced the variation in quality, lowered material waste, and improved the overall manufacturing process.

With lower costs, higher production rates, and exceptional repeatable quality, Die casting customers can now expect denser, more durable, and stronger parts.

Die Casting Processes and Machines

By the tonnage of the clamping force they provide, Manufacturers classify both cold chamber and hot chamber die casting machines. From 400 tons to 4,000 tons, the size of die casting machines ranges. They all have the same basic purpose regardless of the die casting process or the size of the machine to cast a part using injected molten metal. There are two types of processes:

Cold Chamber Die Casting — To move the molten metal from a holding furnace into the unheated shot chamber or injection cylinder, this machine utilizes a ladle. To deliver a shot into the die, the system relies on a hydraulic piston. Cold chamber casting is a slower process as compared to the hot chamber casting method. Nonetheless for manufacturing aluminum parts, it works great. However, molten aluminum alloys can shorten the lifecycle of dies, and damage and attack the metal cylinders or plungers.

Hot Chamber Die Casting — immersed in a molten metal pool, this machine employs an injection system. The furnace connects to the machine through a gooseneck, or metal feeding system. Allowing the molten metal to fill the gooseneck from a port in the injection cylinder, the piston retracts at the start of the cycle. Through the gooseneck and nozzle in the die, the downward action of the plunger forces the molten metal and seals the port. The plunger pulls upward after solidification; the part system ejects the part after the die opens.

From a separate furnace, a hot chamber dies casting eliminates the need to transfer metal. However, only for low melting point alloys that do not damage the injection cylinder, such as magnesium, zinc, copper and lead, the process of die casting services is feasible.

The most important factors to consider are machine performance as it relates to clamping force when selecting a die-cast machine.

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