Production Advantages of Die Castings Used for Car Parts. Strength and durability – These are the most important requirements for automobile parts. Nowadays, the industry has a strong demand for die castings used for car parts. Die casting is a …
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Difficult Die Casting Molds
Kinetic Die Casting Company makes die casting parts from die casting molds that other die casting companies will not use. If you have a tool that “needs” replacement, call us and we can make your old die casting tool work in our die casting machines.
In 1995, a medical device manufacturing engineer brought over a die casting mold that he made overseas. He had saved over $20,000 making this tool overseas instead of a local die casting company. He had taken this mold to several other die casting companies to get a price for production parts. The tool was made of a material that was not tool steel. The material was soft. The size of the mold was half the size it should have been to produce the parts. The mold had slides that were “pinned” together with soft wire pins. And the mold base was damaged.
I took the die casting mold to a local die casting competitor, who I knew had experience running these types of jobs. He told me he would not touch the job because it would more likely be problems than rewards. He suggested I send the tool back to the customer and say “thanks but, no thanks”.
I decided to try to run this job because I did not really know what to expect. I was surprised at how many problems could occur. Every time a part stuck in the die, the cavity could be damaged by our die casting machine operator from using hardened removal tools. The mold base being under sized caused thermal transfer problems. The slides pulled apart because they stuck in the casting. The gate and runner system washed out because the steel was too soft to maintain the gates. The thermal problems and the gate washout caused porosity in the castings.
Over the years I have re-welded the parting line with H13 tool steel to harden the surfaces. I have replaced the wire pins that were used to hold the slides in the mold with hard steel pins. I have replaced or rather installed pins and bushings in the mold base. I have re-gated the tool three or four times. While making over 30,000 parts on this die casting mold, I have learned several valuable lessons.
Over the past 15 years, Kinetic Die Casting Company has taken on several more of these “problem die casting tool jobs”. I am happy to say that these jobs are only a challenge to my people. All I can say is if you have a difficult die casting mold or die casting tool, bring it to us for great quality parts.
Kinetic Die Casting can manufacture aluminum automobile parts, heat sinks, aerospace parts and much more. If you are looking for aluminum or zinc parts, visit our website Kinetic Die Casting Company
Posted in Tooling Die Casting
Tagged Die Casting Company, Die Casting Process, die casting tooling, Manufacturing, Porosity
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Beginnings of Die Casting
Beginnings of Die Casting. Die casting was invented by Elisha K. Root in the 1830s. She was an inventor in the employ of Samuel W. Collins’ ax-making company in Canton, Connecticut.
As early mid-1800, the first examples of die casting occurred. In 1849, a patent was awarded for the first manually operated machine for casting printing type. Development of other shaped began toward the end of the century. In the early 1900s, mass production of parts of phonographs and cash registers began.
The first alloys used in die casting molds were compositions of tin and lead. Their use decreased when zinc and aluminum alloys were introduced in 1914. This was soon followed by magnesium and copper, and by the 1930s, more modern alloys were introduced.
The process of die casting developed from low-pressure injection to high-pressure die castings. These modern processes, squeeze casting and semi-sailed die casting, produce high integrity castings.
Developments in the refinements of alloy as well as the process of die casting continued. Die casters now produce castings in many sizes and shapes. These castings are also durable and dimensionally precise.
Die castings is one of the mass-produced items in metalworking. Die casting parts are found in consumer, commercial and industrial products. They are one of the biggest volume items produced by the metalworking industry.
Dies, or die cast tooling, die cast tools and die casting molds have efficient styles, sizes and values. They come in single cavities or multiple cavities. Some die cast tools cost a few hundred dollars for trim dies. Cavity inserts cost a few thousand dollars while a complete die cast tool package costs several thousand dollars.
Kinetic Die Casting manufactures zinc and aluminium die casting. If you would like a quote, please visit our website:Die Casting quote
Posted in Diecasting Process
Tagged Die Casting Company, Die Casting Parts, Die Casting Process
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Magnesium Compared to Zinc
Magnesium Compared to Zinc – Die Casting Characteristics. Die casting has been getting lots of attention lately for its overall usefulness to the manufacturing process. How much it lessens production costs and production time has been proven to be very significant.
However, the metal being used for the die casting process has always been under debate. Both magnesium and zinc have their own properties which make manufacturers choose one over the other. Magnesium compared to zinc – what does one have as an advantage over the other?
Zinc is agreed upon by manufacturers as the easiest alloy to cast because it has very high ductility. Molten zinc can easily be stretched and shaped into the molds used for die casting. Zinc also has high impact strength, for die casts which need a lot of pounding and shaping to form.
Magnesium, on the other hand, is the easiest alloy to machine. After the die casting process, once the mold has done its job, machining is required for the finer details, and this is where magnesium shines because of its softness to machine over zinc. It is also much lighter than zinc, which is very important in the current trends of industry where lighter is better.
On paper, magnesium compared to zinc looks like a better metal to use in die casting. However, it is still of course up to the manufacturer which alloy to use for the process.
Aluminum Die Casting Everywhere
Aluminum Die Casting Everywhere. Aluminum is turning out to be one of the most important metals in this age of modern industry. It has a lot of uses. One of them is as material for die casting parts. A cursory inventory will show us aluminum castings in a wide range of industries, from the automotive industry, the communications industry, the aircraft manufacturing industry, the computer industry, the consumer electronics industry, and the communications industry. A more detailed catalog of aluminum castings to be found around us would include lights and streetlamp housing, lawnmower gear, instrument cases, electronic gadget cases, cooking utensils, automotive parts, airplane parts, outboard motor, aluminum lighting parts.
Aluminum and metal castings in general can be produced by the processes of plaster casting, continuous casting, investment casting, sand casting, permanent mold casting, and die casting. The versatility of aluminum makes this material suitable for all of the metal processing methods mentioned here, but the die cast method is the most common method for aluminum castings. The die casting process entails the melting of the metal, then injecting it into a die cast mold, but not before applying a separating medium on the mold, then cooling the molten metal to harden it. Once it hardens, it takes the shape of the die mold. Next is the process of extracting the product from the mold. The whole thing from start to finish might take only a few seconds on a die tooling machine. The whole process is then repeated on and on. This is how the world is being supplied with aluminum die castings.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Die Casting Methods and Applications
Die Casting Methods and Applications. To produce die casting for specific applications, the following variations on the basic process can be used. “Squeeze casting” is a method that yields high quality, dense, and heat treatable components. In this method, molten alloy is cast without turbulence and gas entrapment at high pressure. Another procedure is the “semi-solid molding”. Semi-solid metal billets are cast to give dense, heat-treatable castings with low porosity.
Sophisticated methods to automate the die casting process are used by modern die casters. These methods provide continuous quality control. Automated systems are used to lubricate dies or die casting tools and die casting molds. These systems are also used to ladle metal into cold chamber machines, and integrate other functions like quenching and trimming castings.
Microprocessors obtain metal velocity. They shot rod position and hydraulic pressure and other data. These data are used to adjust die casting machine process. This is to assure consistent castings shot after shot. These process control systems also collect machine performance data. These data are for statistical analysis in quality control.
One of the fastest and most cost-effective methods for producing a wide range of components is die-casting. To be able to maximize benefits from their process, it is important for the designers to coordinate with the die caster during the early part of product design and development. This way, issues affecting die cast tooling and production are resolved, while identifying trade-offs affecting overall costs.
For more information on die casting designs, there are a lot of websites in the internet that may help get insights and details. You may also find online various die casting companies that may help you with your die casting requirements.
Kinetic Die Casting is a aluminum and zinc die casting company. If you would like to know more information, please visit our website:Kinetic Die Casting Company
Posted in Diecasting Process
Tagged Die Casting Company, Die Casting Process, die casting tooling
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