Our customer recently sent us a die casting tool to produce die casting parts. He recently experienced a reject from his customer and he needed our help.

Honeywell Aerospace (aerospace company) uses a quality inspection document, EMS 230, to accept or reject high pressure die casting parts. Our customer supplied die casting parts to Honeywell and these castings were rejected for “Cold Shots”.

Cold Shots are imperfections in the metal flow into die casting parts due to the metal freezing or solidifying prior to the metal filling the die casting cavity. It usually happens when the metal flow is limited or the metal is not the proper temperature or the die casting mold is not the proper temperature. As a great quality die casting company, we solve these issues every week. We control the metal temperature with thermocouples and we control the die temperature in our die casting process.

It can also happen if the die casting tooling or the die casting part is poorly designed. The die casting process needs metal to flow rapidly into the die casting tool to make solid die casting parts. Design of the tool or part can limit that fluid process.

This is what happened in this case:

* The die casting tooling gates into a section of the die casting part of about 0.030″ thick wall thickness. This is thinner than recommended for the metal to flow into the die casting. This restricts the metal flow.
* There are sections of the die casting that are over .200″ thick. Consistent wall thicknesses are critical for sound die castings.
* The prior die casting company added overflows and vents that worked against each other by filling the tool from two or three directions. These gates, vents and overflows created turbulence in the shot process which cause the metal to cool prematurely.

What did Kinetic Die Casting Company do for our new customer?
* We made some fast tooling changes to improve the metal flow in the die casting tool.
* We made great quality die casting parts for our new customer.
* We did this in less than three weeks for our happy customer.

Like Us    Join Us  Follow Us

Contact Kinetic Die Casting Company for your metal products. 818-982-9200 or sales@kineticdc.com

Exploring the Process of High Pressure Die Casting. The process of high pressure die casting is one of the fastest and cost effective methods in shaping metal products. Many manufacturing companies in the fields of automotive, aircraft and electronics use die casting as the primary metal working procedure. It produces high quality products with strong yield and fine finish. It provides strength treatment which is far better than forging, extrusion or sand casting.

The procedure involves two dies: the cover die half and the ejector die half. Between them is the mold cavity. When the dies are fitted together, the plane of intersection is called the parting line. During metal working, molten metal is forced to the mold through an opening in the cover die. This is done with very high speeds, due to the high pressure of injection. These are called “shots.” While the metal is still in liquid form, extreme pressure is applied, compressing the dies. This will be maintained until the metal solidifies.

The process of high pressure die casting is further divided into two groups: cold chamber and hot chamber processes. Basically, both employ high pressure shooting and compression of the molten metal. However, hot processes can only be used on metals with lower melting point. These include copper. Cold processes are used on high melting point metals like aluminum and magnesium. Cold processes take a relatively longer time before the shot is compressed at the dies.

In both methods, the process of high pressure die casting is consistent in producing tough products. They are highly resistant to torsional and tensional stresses, making die casting popular in multiple industries.

To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.

Exploring the Process of High Pressure Die Casting. The process of high pressure die casting is one of the fastest and cost effective methods in shaping metal products. Many manufacturing companies in the fields of automotive, aircraft and electronics use die casting as the primary metal working procedure. It produces high quality products with strong yield and fine finish. It provides strength treatment which is far better than forging, extrusion or sand casting.

The procedure involves two dies: the cover die half and the ejector die half. Between them is the mold cavity. When the dies are fitted together, the plane of intersection is called the parting line. During metal working, molten metal is forced to the mold through an opening in the cover die. This is done with very high speeds, due to the high pressure of injection. These are called “shots.” While the metal is still in liquid form, extreme pressure is applied, compressing the dies. This will be maintained until the metal solidifies.

The process of high pressure die casting is further divided into two groups: cold chamber and hot chamber processes. Basically, both employ high pressure shooting and compression of the molten metal. However, hot processes can only be used on metals with lower melting point. These include copper. Cold processes are used on high melting point metals like aluminum and magnesium. Cold processes take a relatively longer time before the shot is compressed at the dies.

In both methods, the process of high pressure die casting is consistent in producing tough products. They are highly resistant to torsional and tensional stresses, making die casting popular in multiple industries.

To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.

How Are Aluminum Heat Sinks Die Castings Made? Heat sinks are used to reduce or remove heat from electrical appliances. Essentially, these heat sinks are used to prevent appliances from overheating and breaking down. Currently, more and more heat sinks are being made with aluminum die castings because aluminum is able to better diffuse heat from electronic applications or appliances and thereby dissipates heat more effectively. Additionally, aluminum heat sinks’ die castings are durable and electrically conductive. The electrically conductive property of aluminum heat sinks benefits manufacturers because aluminum heat sinks’ die castings are cheaper to produce since they do not need added copper plating. Also, the aluminum parts can be electrically grounded and are used for EMI and RF shielding. Another benefit to manufacturers when using aluminum is that the metal is very abundant and can be easily extracted from the earth’s crust.

Aluminum heat sinks’ die castings are produced by first melting the aluminum. Once the aluminum is melted, the liquid metal is then injected into molds, which will give the aluminum new shapes. Afterwards, the molds are cooled for a while to allow the aluminum to harden. When the molds are cool enough, they are opened to reveal new heat sinks. The die casting method for manufacturing aluminum heat sinks is the best way to produce heat sinks in bulk because it is a reliable, fast, and cheap method.

To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.

Where Do You Find Die Cast Heating Plates? Die cast parts can be found in virtually everything that people use in their day-to-day lives. Die cast heating plates, in particular, are an integral part in various heating tools. Those who are in the mug printing business normally use mug cup heat press transfer machines that have die cast heating plates to ensure superior durability. Other printing businesses also benefit from flat heat transfer machines (which also make use of heating plates) to transfer images or designs to t-shirts, jigsaw puzzles, ceramic titles, ID badges, placemats, coasters, door hangers, mouse mats, and other flat surfaces on which designs can be printed. In households, various appliances and devices have die cast heating plates. For instance, many kitchenware items, such as pans, electric griddles, electric hot plates, and heating bases of electrical wok sets feature heating plates. Many steam irons also utilize heating plates to ensure high-quality ironing. Die cast heating plates obviously serve an important role in different kinds of devices and machines that are used in everyday life.

Manufacturers of the aforementioned appliances and machines normally source the die cast heating plates from die casting companies. China has the most number of die casting companies, but there are also quite a number of die casting companies in the United States, such as the Kinetic Die Casting Company based in North Hollywood, California, that may also be able to produce heating plates.

To get a price for aluminum die casting parts or die casting tooling, call toll free 800-524-8083 and ask for sales. Or email us at sales@kineticdc.com for a fast response on a price quote.