Die Casting Process

For Large Industries: The Process of High Pressure Die Casting

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May 212020

For Large Scale Industries: The Process of High Pressure Die Casting. The process of high pressure die casting is popular among large scale production lines. It is considered as one of the most cost effective and fastest metal working process, when compared to forging, sand casting and other types of machining. Traditional die casting is also called high pressure die casting because the molten metal is forced into the mold cavity by using high pressure.

The mold cavity is formed by two halves. They are the cover die and the ejector die. The section where the two halves meet is called the parting line. During casting, molten metal is injected between the dies. The metal is allowed to flow through an opening in the cover die half. High pressure, between 10 to 175 mPa, is maintained until the molten metal solidifies. This process of high pressure die casting ensures uniform solidification of the final product. Hence, it produces uniform work pieces with high yield strength. There are two types of the method: cold chamber and hot chamber casting. The choice depends on the melting point of the metal. For example, zinc and aluminum alloys can only be processed in cold-chamber environments.

The process of high pressure die casting has many applications, ranging from the toy industry to automotive and computers. The technique also minimizes, if not totally eliminates, post-machining like sanding or grinding. Therefore, there are less post-production costs. However, this technique is only recommended for large scale businesses. The initial cost of construction of dies, due to painstaking details and strength, is relatively higher than other machining processes.

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 E-mail sales@kineticdc.com for a fast response on a price quote.

Kinetic Die Casting manufactures aluminum die castings creating aluminum die casting boxes, aluminum handle hardware, and aerospace die casting. If you would like to get a quote, please visit our website: Kinetic Die Casting Company

Kinetic Die Casting manufactures products like heatsink die casting, aluminum housings, and lighting fixtures. If you would like more information, please visit our website:Kinetic Die Casting Company

Die Casting Process
What is Die Casting?
Aluminum Die Casting Prices
Why Should You Use Die Castings?
Kinetic Die Casting Company

Kinetic Die Casting Company 6918 Beck Avenue, North Hollywood, California 91605 USA
E-mail sales@kineticdc.com Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877
Die Casting Parts Prices

A Comparison: Die Cast Parts or Plastic Parts 2020

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May 142020

A Comparison: Die Cast Parts or Plastic Parts. Within the past decade, plastic molded products have become plentiful in the market. More and more plastic products are being shaped as extra to metal products such as faucet, door knobs, and chair braces. Die casting manufacturing industry is facing an opposing that produces products that do not disintegrate or rust. However, the question is, which is actually better, Die Casting Parts or Plastic Parts?

Durability

Die cast parts are essentially stronger likened to their plastic counterparts. In cases that a material is desired to be built thin and yet tough, die cast parts are desirable. Also, die casting parts can endure a wider range of temperature than their plastic counterparts, permitting them to be more ideal in severe working environments with dangerous temperatures.

Furthermore, since, die casting manufacturers use non ferrous type of metals like aluminum, zinc and magnesium, the quarrel that die cast parts are most probable to corrode easily lacking out of the picture.

Environmental Issue

When it comes to issues with environment, plastic products do not promise very well. If you wonder how long plastic products biodegrade, then the answer is: it takes at least few hundred years. This suggests that old and non-practical plastic products are going to flood the landfills. Likening these plastic products to die cast parts, the latter is really made of recycled material. About ninety five percent of metal utilized in die cast parts production is recycled from recovered parts. With this, metal is established to be a more maintainable material that could be used not only once but countless times over.

A Comparison: Die Cast Parts or Plastic Parts

Steel Parts or Plastic Parts or Die Casting Parts
Metal or Plastic Parts
Custom Metal Part Castings
Die Casting Parts Porosity
Die Casting Pats Photos

Kinetic Die Casting Company 6918 Beck Avenue, North Hollywood, California 91605 USA
E-mail sales@kineticdc.com Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877
Die Casting Part Prices

The Die Casting Part Production Process Explained 2019

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Dec 122019

What is the Die Casting Process? The Die Casting Part Production Process Explained.

Kinetic Die Casting Company uses a manufacturing process called “Die Casting” to make aluminum die casting parts and zinc die casting parts. But, what is the die casting part production process? Here is a GIF image I have on our home page to demonstrate:

demonstration of the die casting process

“Aluminum die casting is an aluminum metal parts production process where molten aluminum metal alloy is injected into a steel die, under extreme pressure, to manufacture aluminum parts” (Substitute the word “zinc” for “aluminum” in zinc die casting part production process)

Another GIF example example is on this web page:
(click) What is Die Casting?

Another demonstration of the die casting process
Cold Chamber High Pressure Die Casting Machine

Cold Chamber Die Casting Process

The image pictured above depicts a Cold Chamber Die Casting Machine as it makes parts. The term “Cold Chamber Die Casting” refers to a separate metal melting furnace. The High Pressure Die Casting, cold chamber die casting process follows this sequence:

Look at the die casting machine image above

The die casting machine opens the die casting mold.
The prior part is removed and the die cast mold is sprayed for the next part
The aluminum is poured using a ladle into a shot cylinder
The shot piston injects the metal into the die casting mold.
The machine opens and the process starts again.

Contact Kinetic Die Casting Company for more information about the high pressure die casting process and about how to get great die casting parts at a great price and delivered quickly, no matter what quantity you need.

Kinetic Die Casting manufactures aluminum military parts, aluminum hardware, and aluminum die castings. Visit our website for a quote: Kinetic Die Casting Company

500 Shots Daily

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Jul 252019

Kinetic Die Casting Company uses a process of making 500 to 1000 aluminum die casting parts every day. Last week, in my multiple cavity die casting tool article, I briefly described the die casting shot cycle as: Die Open, Spray, Die Close, Inject Metal, Open Die, Eject Part and Repeat. This takes about one minute each shot cycle.

die casting production cycle

Die Open – The hydraulic system opens the die casting machine platens. The die casting mold is attached to the die platens, opening the die wide so the two halves can be accessed.
Spray – Molten metal will stick to the steel die if a release agent is not used to coat the tool. The cavities, the slides, the core pins and ejector pins are sprayed also to cool them down.
Die Close – When the die has been sprayed the machine is closed with hydraulic pressure so the two die halves are closed and sealed together. Sometimes, high pressure nitrogen gas is used to speed the die closing.
Inject Metal – The metal is poured into the shot sleeve and a piston drives the molten metal into the mold. Hydraulic pressure is used to push the metal into the mold. Higher pressures are applied to push out gasses that cause porosity. High Pressure Nitrogen Gas is used to accelerate the piston faster and to add more pressure to squeeze out gasses.
Open Die – The die casting machine opens the platens
Eject Part – The Die casting machines moves a movable platen to push against the ejector plate. The ejector plate pushes the ejector pins. The ejector pins push the part out of the cavity
– Repeat

In a nutshell, This is the die casting shot cycle. Each shot cycle takes about a minute to complete. We make 500 parts a day with a single cavity die.

Permalink: https://www.kineticdiecasting.com/kdc/500-shots-daily/

“The Parts We Make Today, We Ship Today”

What Are Die Casting Parts?
Die Casting Aluminum Heat Sinks
Aluminum Boxes Die Castings
Aluminum Parts or Plastic Parts

Kinetic Die Casting Company 6918 Beck Avenue, North Hollywood, California 91605 USA
E-mail sales@kineticdc.com Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877

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May 162019

Kinetic Die Casting Company uses the die casting process to make aluminum die castings and zinc die casting parts. The die casting process, simplified, is described as follows:

Our customer provides us tooling (https://www.kineticdiecasting.com/tooling.html), a die, a mold or inserts that we use to make their parts. We can also produce the tooling for our customers.
We put together the tooling and mount the tooling in our die casting machine. This takes a few hours.
We fill a furnace with the proper die casting alloy metal (https://www.kineticdiecasting.com/Alloy_Data.pdf) to make the parts for our customer. The metal takes 4 hours to melt to the casting temperature.
While the furnace is heating up we heat up the tooling to make the castings.
When the tooling is hot and the furnace has melted the aluminum, we begin the die casting process.
We spray the tooling with a release agent so the parts do not stick in the tooling.
We close the tooling inside our die casting machine.
The metal is ladled into a shot sleeve, a piston drives the metal into the tooling using great force.
Our die casting machine opens, the ejector pins push the part out of the tooling
We begin the process again by spraying the tooling.
We repeat this process 200 times to 500 times in a 10 hour shift.
When completed making raw castings, we trim the excess material called “flash”. We use a trim die in a trim press or we sand parts with a belt sander and file them by hand. Sometimes this takes longer than the casting process.
At this point, some parts are put in boxes and shipped the same day. Other parts are machined. Some parts get painted or chemical coated. All parts are inspected prior to shipping to our customers.

This is a very simplified description of the die casting manufacturing process.

“The Parts We Make Today, We Ship Today”

Kineticdc makes:
What is Die Casting
Die Casting Part Pictures
Quote Die Casting Part Prices
Diecast Tooling

Kinetic Die Casting Company 6918 Beck Avenue, North Hollywood, California 91605 USA
E-mail sales@kineticdc.com Toll Free: (800) 524-8083 Local: (818) 982-9200 Fax: (818) 982-0877

Permalink: https://www.kineticdiecasting.com/kdc/die-casting-process/

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