Kinetic Die Casting Blog

Materials that are used for casting and used in conjunction of die cast molds come in many forms. And the choice of which materials to use will depend on the manufacturer and will depend on the characteristics of the material alloys. Each of the following materials and alloys has its own properties and benefits, and manufacturers often choose from among these materials and weigh the pros and cons of the alloys and materials.

The main materials or alloys used include zinc, aluminum, and magnesium, copper, lead and tin. The alloys and have its own set of advantages and benefits when used and it is imperative that industrial manufacturers should know what makes one alloy or material superior to the next one. In terms of the material that is easiest to cast then that material is zinc. This material is known for their high ductility, for high impact strength and will be known for its economy. The aluminum material is known for its light weight and known as the material that with high dimensional stability when used for complex shapes and thin walls. The material is known to be reliable against corrosion and has good mechanical properties.

The magnesium is the alloy that is easiest to machine and known for its excellent strength to weight ratio. Copper is another material used in conjunction with the die casting molds and the alloy form copper is known for high hardness and a better material that can withstand corrosion. Lead and thin are two other alloy materials used when casting.

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There are many forms of Die Casting Porosity, many are caused by these die casting variables:

• Metal Temperatures and Mold Temperatures.
• Material Cleanliness.
• Die Casting Mold Design.
• Die Casting Part Design.
• Die Casting Machine Pressures.
• Die Casting Machine Shot Speed.
• Die Casting Spray or Die Casting Mold Release.
• Other forms of porosity can be from “shrinkage” or wall thickness.

What is Die Casting Porosity? In order for you to know what die casting porosity is, you need to know the die casting basics. The most common form of Die Casting Porosity is a kind of factory defect in which die cast parts contain small pockets of void space and air within the metal, causing it to become porous.

Porosity in Die Casting is the air trapped by the metal inside the die casting parts. To know more, a basic knowledge of the die casting process is necessary. Die casting is a process wherein a particular amount of molten metal is put inside a shot cylinder, then it is applied (plunged) with great force with a piston so as to force the metal into a die cast mold or die cast die. During this “plunging process”, air inside the cylinder is forced along with the metal into the die casting mold. It is a very fluid turbulent process. The air forced into the mold with the metal and the metal already inside the mold is forced out of the mold through a series of gates, vents and overflows.

After this, the metal is left to cool down and harden or freeze inside the mold. The metal is then removed as a die cast part. The same process is repeated over again.

Die casting companies use metals which are non-ferrous, or do not contain Iron, as this is the highest factor for oxidation and rusting. Several examples of non-ferrous metals include zinc, aluminum, lead, magnesium, tin and copper. Kinetic Die Casting only uses aluminum and zinc.

In the worst case, porosity in die casting parts, weakens die casting parts, if the voids or pockets are very large. Porosity typically matters most in pressure tight die casting parts. When the air escapes through a die casting part, it is typically caused by porosity.

Employees of Kinetic Die Casting are POROSITY EXPERTS in die casting parts that need to be free of porosity. http://www.kineticdiecasting.com/porosity.html

What is Consumer Parts Die Castings? Die Casting Tooling are tools used in a process known as die casting. In this process, the metal alloy which can be zinc, copper or aluminum, is melted into liquefied metal by heating it in intense temperatures. After the metal alloy is liquefied, this will then be poured into the die casting tools and after it cools down, it becomes the finished product. This process is commonly used to create consumer parts. Consumer Parts Die Cast Tooling is the fastest and cheapest way to make bulk numbers of parts that are commonly used in everyday items.

Consumer Parts Die Castings come in many forms, shapes and sizes. This process is very useful to many manufacturers around the world as aluminum parts are used almost anywhere and everywhere. Automobiles rely heavily on aluminum parts, the same goes with lighting fixtures and consumer electronics. Heat sinks and brackets are usually made of aluminum because the properties of this metal alloy are perfect for the purpose.

There’s a huge demand for Consumer Parts Die Castings. Any manufacturer can lower his or her cost by applying this technique in making parts for new products. If a manufacturer doesn’t have the resources to purchase the machinery required for die casting, then it could opt to contract the services of another company which offers die casting jobs. Their services are available all over the country and around the world for that matter. Sometimes overseas companies can offer cheaper rates even with higher transportation costs with the same or even higher quality of the finished product.

WHAT IS DIE CASTING? The process of die casting provides the backbone to the functioning of the major heavy and even light metal industries and especially in developed economies such as the US. Most of the raw material parts in hardware, auto and locomotive industries are a product of this vital process. Here is simple and short guide get elemental knowledge about this technique.
To define in a simple layman tone, die casting is a process where at high pressure and controlled conditions, molten metal is poured or forced into casts or molds and consequently give them solid definite shapes for desired purposes.

THE FOUR STEP PROCESS

• The cast is readied for pouring in the molten metal. This is done by lubricating the walls of the mold so that when the metal solidifies it is easier to take it out. The lubricant also helps in maintaining the perfect temperature for the process.
• Next the liquid metal is forced into the cast; a more technical terminology would be “shooting” the molten metal inside. It is very important that the constant high pressure is maintained at this stage. The pressure is usually ranged from 1500 to 2500 psi.
• The next step is to open the cast and then the shot/shots are taken out using ejector pins.
• The last step is to separate all the waste or scrap such as gate, runner, sprues form the pure cast of the metal.

The cast which are used are preferably made out of non ferrous metals such as copper, zinc, magnesium, aluminum and the like. In the present day the demand for aluminum products is sky high and so is the supply through aluminum die casting.

How Are Die Cast Parts Manufactured? In manufacturing die cast parts, technology plays a significant role. Today, there are several sophisticated methods that modern die casters can turn to in order to automate the die casting process and ensure effective quality control. These things are important as the demand for die cast parts continue to grow. There are now automated systems designed to lubricate dies, ladle metal gently and accurately into cold chamber machines, and unite other operational tasks, such as trimming castings and quenching them. There are also microprocessors that can obtain hydraulic pressure, shot-rod position, and metal velocity; they help in making sure that consistent castings are done one shot after another. Aside from these functions, such process control systems can also simultaneously retrieve necessary data related to performance for better assessment and enhanced quality control, allowing more efficient manufacturing.

Die casting design is another important aspect of making and manufacturing die cast parts. In order to gain maximum benefits as far as cost-efficiency is concerned, it is imperative that die casters collaborate with die cast designers at the early stages of product development. Consultation is the key to resolving issues of considerable value, such as tooling and machining additions, labor issues, and other trade-offs in business that can contribute to the increase or deduction of overall costs. Traditional die casting designs can be found in textbooks, trade journals, technical papers, professional association newsletters, and online articles. Once the designs are reconciled and approved, the production of die cast parts may continue without trouble.