What is Pressure Die Casting?
Pressure die casting is a manufacturing process that involves injecting molten metal into a die cavity under high pressure. This process is used to produce complex shapes with tight tolerances and excellent first-rate surface finishes. It is a cost-effective way to produce exquisite parts in large quantities. It offers a number of benefits over other manufacturing processes, inclusive of shorter lead times and improved dimensional accuracy. Additionally, the process is highly repeatable, allowing for consistent production of parts with minimal variation. It is an ideal solution for producing parts with intricate details and complex geometries. Additionally, the process is fast, efficient and value effective. Components produced using pressure die casting are incredibly strong and durable, since the high-pressure injection ensures that the components hold their shape even under extensive amounts of pressure.
The molten metal is typically a non-ferrous alloy such as aluminum or zinc however different metals can also be used. The pressure die casting process can create parts with precision tolerances and uniformity, as fine as 0.001” or less.
The processes involved in it are,
Step 1: The pressure die used in the process must be designed specifically for the component being produced. It must be crafted from hardened tool steel and ought to be designed with cooling channels and venting holes to ensure that the molten metal can flow freely and be removed fast.
Step 2: The second step is to set up the die casting machine. It should be securely mounted with any necessary modifications required. The die must be securely clamped into the die casting machine. The pressure die casting machine is capable of generating forces of up to 15,000 psi.
Step 3: The next step is to prepare the metal that will be cast. The metal is melted in a furnace and poured into a ladle. The molten metal is usually poured at temperatures between 750 and 1000 degree Fahrenheit. The molten metal must be kept molten and must be stored below the material’s melting point.
Step 4: Now, inject the molten metal into the die. When the desired pressure is applied, the molten metal is forced into the die at high speed. Pressure is maintained throughout the entire injection process.
Step 5: After the metal has been injected into the die, it is allowed to cool and solidify using air, liquid coolant or a combination of the two. During this process, air is also released from the die, which prevents the metal from becoming confined.
Step 6: Once the part has cooled, the final step is to unclamp the die and the elements can be removed from the die. The pressure die casting process is complete and the elements are prepared for finishing and inspection.
1. High Pressure die-casting
It is the most extensively used form of pressure die-casting. It involves the usage of high pressure to pour the molten metal into the mold cavity which ranges from 1500 to 25000 PSI [about 170 Mpa] in higher velocity. This process is ideal for producing components with intricate details and complex shapes.
2. Low Pressure die-casting
This process uses low pressure to inject the molten metal into the die. Its acting pressure is relatively low ranges from 2900 to 8700 PSI [20 to 60 Mpa]. High first-rate castings of aluminium alloys, magnesium and different low melting factor alloys are normally produced through this process.
MATERIALS
Ultimately, the choice between high pressure die casting and low pressure die casting relies upon the specific needs of the project. Zastata can help in choosing the right process and right manufacturer at competitive price.
Aluminium and its alloys like A360, A380, A383
Zinc
Aluminium Zinc Alloys [ ZA-8, ZA-12, ZA-27]
Magnesium Alloys [ AM50A, AM20, AM60B, AS41B, AE42,etc,]
Copper
Other alloys consisting of tin, lead, Brass and Cobalt may also be used depending on the attributes required.
After removing the production components from the diecast, they are subjected to one or more finishing processes to remove the gates, overflows, and any flash or similar unwanted components. Finishing is also used to smooth out the parting lines on the component.
The Finishing Processes
We also provide some Finishing Processes like
- Polishing, Sanding, Deburring, Grinding, etc.
- Abrasive Blasting techniques like shot blasting – to roughen a smooth surface is required.
- Painting and Powder coating – to enhance physical wear resistance, prevents corrosion and improves aesthetics.
Secondary Operations
Some of the secondary operations we perform are:
- Trimming – to remove this excess material in mold segments referred as flash.
- Machining – to ensure features like holes, threads, undercuts, and many others which can be unachievable by way of casting technique.
- Heat treatment process – to enhance material properties based on requirements
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
Quality Certifications
We work with manufacturers who hold certifications like:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
OTHER TYPES OF CASTINGS
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages of Pressure Die casting,
- More economical with larger extent of production
- Able to provide castings with thin walls and lighter in weight.
- It is a cost-effective and efficient manufacturing process that produces high-quality, complex parts with tight tolerances.
- Shorter lead times, improved surface finish, and greater design flexibility.
- More environmental friendly process, since it produces minimal waste and requires fewer resources than other manufacturing methods.
Some of the application where Pressure diecast components are used:
- Automotive parts like cylinder heads & blocks, automotive manifolds, body panels, heels, structural brackets, etc.
- Aerospace castings.
- Llightweight aluminum components for helicopters, aircraft and satellites
- Medical equipment’s.
- General hardware appliances, pump parts, plumbing parts, Electric motor housings, Kitchen wares.
- Cabinets for the electronics industry.
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