High Pressure Die Casting

Description

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies and work similarly to an injection mold during the process. The typical material for high pressure die casting are aluminum, zinc, magnesium, copper, and tin-based alloys. Depending on the type of metal being cast, a hot, or cold-chamber machine is used. Auwell typically provides services for hot chamber aluminum and zinc die casting molds and products.

High pressure die casting can be done in a single or multiple cavities, use of unit dies or a combination of dies depends on the product requirements.

Different type of dies in the die casting process:

-Single cavity to produce one component

-Multiple cavities to produce several identical parts

-Unit die to produce different parts at one time

-Combination die to produce several different parts for an assembly

The casting equipment and the metal dies represent large capital costs. It is thus especially suited for a large quantity of small to medium sized castings, which is why high pressure die casting produces more castings than any other casting process. High pressure die casting is characterized by an excellent surface finish (by casting standards) and dimensional accuracy.

High pressure die casting is now considered as an industrial procedure, used to manufacture parts for sale, or as part of machines for any other commercial or industrial production. The process allows production of accurate products to the desired size, shape, and thickness with tight tolerances, making it the most simple yet effective casting process, essential for creating metal parts with specified details and quality demands.

High pressure die casting is proven as beneficial to products. In this process, various modifications can be made to the production. Manufacturers spend less funds and less time in the making of the produced die-cast parts which are more attractive to the eyes of the buyers.

High pressure die casting can eliminate post-machining and repeated molding. The process is very economical and finished products made under this process are accurate and long-lasting.

High pressure die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have a long service life and may be designed to complement the visual appeal of the surrounding part.

Advantages of high-pressure die casting are as following:

-High-Speed Production

High-pressure die casting supports complex shapes within closer tolerances compared to many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.

-Excellent dimensional accuracy and stability

High pressure die casting produces parts that are durable with dimensional consistancy while maintaining close tolerances. They are also heat resistant.

-Strength and weight

High-pressure die casting parts have considerable high tensile strength at 415mpa. Thin wall castings are stronger and lighter than those possible with other casting methods.  

-Multiple finishing techniques

High-pressure die-cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with minimum surface preparation.

-Simplified assembly

High pressure die casting provides integral fastening elements, such as bosses and studs. Holes can be cored and made to size using tap drills, external threads can otherwise be cast.

Auwell offers various types of services to fulfill the clients’ requirements. We have a rich experience in designing and manufacturing high pressure die casting tools for the worldwide market, especially EU countries. We produce dies and cast products, including machining and surface treatment, for our clients.

Technical Specifications 

-Core Element Material

H13, 1.2344 (X40 CRMoV51), 1.2367(X38CrMoV5-1), H11, 1.2343 (X38CrMoV5-1)

Bolster Material:P20, 1.2312, 1.2738

-Standard Components

HASCO, LKM standard or custom made

-Popular Product Material

AL226, AL230, AlSi10Mg, 360,380,383, 413 and A304 K-alloy, ADC12, ADC10, Zamak 3, Zamak 5, ZA-8, ZA-12 and ZA-27 etc.

-Product surface finishing

Includes but is not limited to: brush, line polishing, high gross polishing, mirror polishing, sand blaster, anodizing, zinc-plating, chrome-plating, nickel-plating, powder coating, silver coating, E-coat, wet paint, silk screening and stenciling etc.

-Maximum Machining Closing Force

4,000 tons, part weight: 5-30,000g

Advantages

-Rich Experience

More than 20 years of experience in high pressure die casting products development and production, especially to the European and North American markets, with solid understanding of the material, technical and quality standards worldwide.

-Fast Turnaround

Generally, we provide a quotation within 3 working days. Combining the latest manufacturing technologies and facilities, Auwell can provide initial samples in just 5 weeks for simple projects.

-Comprehensive Solution Provider

Auwell provides comprehensive services for high pressure die casting projects starting from designing, through prototyping, tooling/fixture development, sampling, mass production, and to logistic and post-sale support.

-Rigid QC Policies

The most rigorous quality policy starts from material control, and is followed through to final pre-shipment inspection. Material certificates include the mill certificate, 3rd party chemical components, and mechanical property reports, as well as RoHS and REACH reports upon request. Other reports include dimensional reports, surface treatment thickness, and salt fog test reports, etc. We structure our processes, creating Flow Charts and Control Plans before production, making sure all QC processes are in accordance with ISO9001-2015 requirements and drawing specifications.

-Flexible Payment Term

For mass production, we offer flexible payment terms, reasonable credit terms will be given, the client only pays when they are happy with the product they received. For long-term projects, we offer call-off inventory services for fast delivery requirements.

Applications

High pressure die casting products have widely been used in almost all industrial sectors including: 

-Aerospace and defense

-Automotive

-Agriculture Machinery

-Energy

-Electronics

-Construction

-Transportation

-Industrial

-Consumer Products

The following catalogues of high pressure die casting products are the ones which Auwell has produced and supplied to our distinguished worldwide clients. Please click the relevant pictures for details. Please be advised, most of the products are for demonstration purpose only.

Aluminum Die Casting Automotive Parts

Aluminum Die Casting Industrial Parts

High Pressure Die Casting Tooling

High Pressure Zinc Die Casting Parts