Die Casting - ARES Prodcution
Die Casting is the go to option for manufacturing aluminium, zinc and magnesium parts in volume. Our engineering team are highly experienced with the production of die cast parts and will be able to assist you throughout the entire process. We also offer tool design, drawing and validation services to help prior to production.
What is the Die Casting?
Die Casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity, and the mold cavity is created using two hardened tool stell dies which have been machined into shape and work similarly an injection mold during the process. It is quick, reliable and cost-effective manufaturing process for production of high volume, metal components that are net-shaped have tigh tolerances. Basically, the pressure die casting process consists of injection under high pressure a molten metal alloy into a steel mold. Pressure die casting is an ideal method for making large quantities of metal parts with excellent surface finish and dimensional stability. We provide cast parts in aluminum, zinc and magnesium.
Advantages Of Die Casting
We have a range of on site and subcontracted finishing options including CNC machining, threading/tapping, anodizing, paint and powder coating.
Case Study – See How It Was Made
The Pressure Die Casting Process
There are four steps in traditional die casting, also known as high-pressure die casting, these are also the basis for any of the die casting variations: die preparation, filling, ejection, and shakeout. The dies are prepared by spraying the mold cavity with lubricant. The lubricant both helps control the temperature of the die and it also assists in the removal of the casting. The dies are then closed and molten metal is injected into the dies under high pressure; between 10 and 175 megapascals (1,500 and 25,400 psi). Once the mold cavity is filled, the pressure is maintained until the casting solidifies. The dies are then opened and the shot (shots are different from castings because there can be multiple cavities in a die, yielding multiple castings per shot) is ejected by the ejector pins. Finally, the shakeout involves separating the scrap, which includes the gate, runners, sprues and flash, from the shot. This is often done using a special trim die in a power press or hydraulic press. Other methods of shaking out include sawing and grinding. A less labor-intensive method is to tumble shots if gates are thin and easily broken; separation of gates from finished parts must follow. This scrap is recycled by remelting it.
Materials Used In Pressure Die Casting
The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium. The following is a summary of the advantages of each alloy: Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life. Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures. Magnesium: the easiest metal to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast. Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts. Silicon tombac: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment casted steel parts. Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance. Such alloys are not used in foodservice applications for public health reasons. Type metal, an alloy of lead, tin and antimony (with sometimes traces of copper) is used for casting hand-set type in letterpress printing and hot foil blocking. Traditionally cast in hand jerk molds now predominantly die cast after the industrialisation of the type foundries. Around 1900 the slug casting machines came onto the market and added further automation, with sometimes dozens of casting machines at one newspaper office.
Many finishing options are available for your pressure die casting project including sandblasting, polishing, plating, painting, E-coating, pad printing, silk screening, anodizing, machine finishing and much more. We can advise you on the best choices for your design.
With a range of services to choose from and guaranteed quality thanks to our inspection services you can trust you will receive great parts every time. Contact us today for a free quote!