High-Pressure die casting has been shaping the way manufacturing and transformative industry design state-of-the-art products in today’s modern world. From the creation of complex vehicle parts to innovative industrial and medical equipment and robotics, high-pressure die casting is becoming an increasingly popular manufacturing method for designing and creating a wide range of Industrial equipment.
SANON CASTING is a leading die-casting manufacturer and supplier that specializes in aluminum high-pressure die casting for automotive, aerospace, and emerging industry product designs. In this guide, you’ll discover the technicalities entailed in HPDC, its process, its benefits, and how you can extend the process to manufacture the right tools for your industry.
What is High Pressure Die Casting (HPDC)
High-pressure die casting is an essential manufacturing process. It entails injecting molten metal at high pressure and speed into a steel mold cavity to obtain a specific product form. A mold, also known as a die, is divided into two halves designed to form the desired shape of the final product under high pressure. Molten metal solidifies quickly when cast into both halves of the cavity. The die can be opened upon solidification, and the final product with the desired shape is formed.
Since its inclusion in the production of delicate and important tool parts, high-pressure die casting has become the most prominent method of casting. This is due to its ability to create parts with high durability, fused tolerance, and reduced machining. High-pressure die casting is the preferred choice for manufacturers looking to increase productivity and minimize normal and abnormal material losses.
High-Pressure Die Casting Materials
Lots of alloys can be used for HPDC. However, three metals stand out among others, and they include:
Aluminum
Aluminum is one of the most used metals for high-pressure die casting. It is made by cold chamber injection, which allows for a more excellent cycle time than other alloys. Aluminum operates at a temperature higher than zinc and has a better strength-to-weight ratio. In addition, it is less expensive compared to magnesium. However, zinc is much more corrosion-resistant.
Zinc
Zinc is typically used in hot chamber die casting due to its better mechanical qualities. Compared to aluminum, it produces metal casts that are ten times more durable. Zinc melts at a lower temperature, thus accelerating the manufacturing process. However, the prominent disadvantage of using zinc compared to aluminum and magnesium is that it is readily prone to defects.
Magnesium
One of the lighter metals that is frequently utilized in high-pressure die casting is magnesium. Although it favors the hot chamber casting technique, cold chamber casting is sometimes used. Compared to aluminum, cast magnesium has a smoother surface and can be utilized to make thinner walls. However, zinc is lighter and also more corrosion-resistant.
High-Pressure Die Casting Process
There are four essential steps in high-pressure die casting.
Mold Preparation
First, the mold has to be prepared. This process involves applying a lubricant to the inner walls of the mold. The lubricant stabilizes the mold’s temperature and allows for easy removal of the casting.
Injection
The second step of the high-pressure die-casting process is injection. There are two types of injection: the hot chamber injection and the cold chamber injection. The cold chamber injection involves keeping the furnace separate from the machine. The hot chamber injection takes a different approach. Here, the molten metal is constantly heated within the machine itself.
Cavity Removal
The third step is cavity removal. After the molten metal is injected into the die cavity, it has to cool down and solidify to ensure the part retains its shape when removed. Once the metal solidifies, the die opens, and ejector pins are activated to push the cavity out of the mold.
Trimming
The high-pressure die casting process usually produces much waste and scrap metal. The need to remove these scrap products gives rise to the final step, which is trimming. It involves sorting and separating waste or scrap metal from the newly formed product.
Benefits of High-Pressure Die Casting in Manufacturing
High-pressure die casting has so many advantages. The benefits are expressed as follows:
- For large-volume production, high-pressure die casting is the ideal option. It is efficient and precise and produces many parts within a short period.
- Its precision and speed reduce waste and lower cost per unit. This optimum efficiency makes high-pressure die casting the most cost-effective option for large-scale production.
- Apart from being cost-effective, HPDC also gives products detailed features, consistent dimensions, and smooth surfaces that allow for the application of coating for additional features that contribute to their aesthetic value.
- HPDC’s high pressure also allows extremely thin casting walls, making it ideal for aerospace electronics and automotive industries, requiring lightweight yet highly functional parts.
Where Is Pressure Die Casting Used?
In Aerospace
High-pressure die casting is very important in the aerospace industry. The industry demands careful precision in every component, from the smallest part to the largest. That is why aluminum die casting uses the production of smooth, lightweight components, such as airframes and engines.
In Medicine
High-pressure die casting also has applications in modern medicine. It is used in manufacturing surgical equipment such as heat sinks for implants, forceps, x-ray equipment, and scissors.
In Automotive
Automotive industries use high-pressure die casting to produce large automotive parts. This is HPDC’s primary market. Essential components like engines, drive trains, wheels, chassis, and bodywork are built using HPDC.
Quality High Pressure Die Casting in China
High-pressure die casting provides a solution for industries looking for a balance between strength, complexity, and production efficiency. It helps curate unique product designs and parts tailored to the functioning of various industrial tools. Aluminum high-pressure die casting can help your manufacturing business enhance its internal and external economies of scale through unmatched product designs.
If you are a manufacturer that wants this, Sanon Casting is here for you. Our expertise in providing high-pressure die-casting services in China allows us to transform your design concepts into durable and highly functional components. At Sanon, we are committed to ensuring your parts meet your specifications every time. Request a quote today, and let’s incorporate the power of die casting into creating your desired tools.
