Die casting is a method that quickly fills mold spaces with hot liquid metal under pressure. It uses molds and machines. This process changes the metal from liquid to solid to create the product.

This changes the metal from liquid to solid to make the product. Below is a detailed introduction to the process, materials, and characteristics of die casting:

Process Classification:

Manufacturers classify die casting based on the injection chamber method into hot chamber die casting (commonly used for zinc alloys) and cold chamber die casting (commonly used for aluminum alloys). According to pressure, it can be categorized into low-pressure die casting (such as automotive wheel hubs) and high-pressure die casting (as commonly used in most die casting facilities). It can also be distinguished by the exhaust method into conventional die casting and vacuum die casting.

Materials and Characteristics:

Common materials suitable for die casting include zinc alloys, aluminum alloys, magnesium alloys, and copper alloys. These materials exhibit the following characteristics:

Good fluidity in the liquid state.
Relatively fixed melting and solidification points.
Small shrinkage rate.
Certain high-temperature strength.
Good processing performance and corrosion resistance.

Main Components and Impurities:

The main components of die-cast aluminum alloys include aluminum, silicon, copper, magnesium, manganese, zinc, etc., while impurities include iron, zinc, copper, tin, aluminum, sulfur, phosphorus, etc. Different alloy grades have different requirements for their main components and impurity components.

Common Defects:

Common defects in die-castings include under-casting, cracks, deformations, cold shuts, cold cracks, shrinkage porosity, gas porosity, mechanical tearing, sticking mold tearing, delamination, mismatch, slag inclusion, surface porosity, foaming, excess metal, and insufficient metal.

Optimal Temperature:

The suitable temperature for the liquid aluminum alloy for die casting production is typically between 650°C and 720°C.

Production Characteristics:

High production efficiency, allowing for mechanized or automated production.
Good product quality, with high dimensional accuracy, surface finish, mechanical properties, and interchangeability.
Good economic benefits, with excellent economic indicators and low die-casting costs. However, die casting equipment and mold investment costs are high, making it unsuitable for small-batch production.
In summary, die casting, as an efficient and high-quality metal forming process, plays a significant role in industrial production. Understanding its process, materials, and characteristics can help improve production efficiency and product quality.