Customized High Pressure Die Casting Aluminum Alloy Die Casting Injection Shot Blasting Aluminum Cast Part

• Customization: Available
• Die Casting Machine Type: High Pressure Die Casting Machine
• Die Casting Method: Cold Chamber Die Casting
• Model NO.: ZSH-001
• Application: Machinery Parts
• Machining: Aluminium Casting Processing
• Material: Aluminum Alloy
• Surface Preparation: Deburring
• Pressure Chamber Structure: Horizontal
• Tolerance Grade: 6
• Casting Surface Quality Level: 1
• Certification: CE, RoHS, ISO 9001:2000, ISO 9001:2008
• Machine Type: Aluminium Injection Molding Machine
• Post Processes: Shakeoff, Trimming, Deburring, Sand Blasting, CNC
• Supply Assembly Parts: Yes
• Surface Coating: Paint, Powder Coating, Anodic Oxidization
• Testing Equipment 1: Salt Spray Testing, X-ray Inspection, CMM
• Testing Equipment 2: Rockwell Hardness, Roughness Profiler
• Testing Equipment 3: Tensile Testing, Spectral Analyzer
• Transport Package: Wooden Case and Carton Box
• Specification: as to drawings
• Trademark: ZHAOSHUN
• Origin: Zhejiang, China
• HS Code: 7616991090
• Production Capacity: 175200PCS Per Year

Product Description

Product Description

What is high-pressure die casting?
High-pressure die casting is a process wherein molten metal is forced, under pressure, into a sealed mould cavity. It is held in place by a powerful compressive power (true die installed in hydraulics machine) until the metal solidifies.

Following solidification, the die is released, opened and the metal is released.

Following removal, the mould cavity is resealed for the next cycle.

Molten metal injection into the mould cavity occurs in a fraction of a second (usually under 100 ms). One time die cavity is filled, extremely high pressure is applied (often over 1000 bar) into a molten metal true injection plunger. This phase is called intensification.

This pressure compresses out any gases trapped in the metal (during extremely fast and turbulent cavity filling) and feeds more metal into the mould to partially compensate for the shrinkage in the metal whilst it is solidifying.

In addition to traditional high-pressure die casting methods, over recent years there have been a number of improvements in the process. For example:

vacuum die casting
semisolid casting
squeeze casting

High pressure die-casting: hot and cold chamber systems
In order to inject molten metal into the mould, two different systems may be used:
a hot chamber system
a cold chamber system
Let's discover more about these two processes.
The hot chamber system
The hot chamber system is used with metals such as zinc, magnesium and lead.
The injection system for a hot chamber machine is immersed in molten metal from the blast furnace. When the piston pumps, it forces metal along the nozzle and into the die.
The cold chamber system
The cold chamber system is used for metals which melt at high temperatures, such as aluminium, copper and magnesium.
Magnesium parts can be produced by using either systems, although generally speaking small parts are made in hot chamber systems, whilst large parts in cold chamber systems, as hot chamber machines have limited dimensions.
In this system higher pressure is used compared to the hot chamber system. The production rate of a hot chamber machine is higher than that of a cold chamber since less time is required for the pouring process.
The cold chamber system also uses two injections systems in the process:
horizontal injection
vertical injections
In this system, the molten metal is poured, either manually or automatically, into an opening leading to a channel feeding the cold chamber.
A piston which is hydraulically activated moves down this steel channel, blocking light and pushing the metal into the mould at high speed and pressure.
Following solidification of the flow, the piston is pulled back, and the mould opened, the flow is expelled and the system is ready to be activated again.

Metal Material For High Pressure Die Casting
Non-ferrous metals are usually used for HPDC because they just fit the bill. Aluminum (particularly 356, 380, 390, 412, 443, and 518) is a common go-to because it's dimensionally stable, corrosion-resistant, electrically conductive, and able to withstand high temperatures. Compared to aluminum, zinc alloys (like Zamak 2, Zamak 3, and Zamak 5) they have a lower melting point, but they're strong and ductile, and can be used with both hot and cold chamber die casting systems.
Magnesium is another option as it's the lightest structural metal, highly machinable, and suitable for hot chamber die casting thanks to its lower melting point. Ideal for high strength-to-weight ratio applications, many Xometry customers prefer using magnesium (like AE42, AM60, AS41B, and AZ91D) for certain automotive and aerospace components. In addition to the aforementioned industries, these materials are also used in the pressure die casting process to make things like consumer electronics, and other decorative items that require intricate shapes or thin walls.
A few of the process's downsides are its high initial cost and material limitations (it can only work with non-ferrous metals). There tend to be size limitations for cast parts, and it can be prone to porosity issues, cold shuts (where two fronts of molten metal meet but don't fuse properly, creating a weak spot), and misruns which lead to incomplete castings or parts that are not fully formed. You may experience flash-excess thin layers of metal that escape and need trimming. This can be minimized, though, by clamping the mold halves tighter. Finally, it can create blisters-a type of gas porosity that looks like raised bubbles on the surface. If you try to minimize any trapped air further, you may be able to avoid this.
 

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