Die Casting

Custom Die Casting Services

JIAHUI offers its customers high precision die casting services to produce customized metal products in no time. Being a leading die casting manufacturer since 2015, we guarantee high tolerance and dimensional accuracy in our custom parts. Our highly skilled technicians ensure the exceptional quality of the molds and parts by implementing the strict operations of the die casting process to satisfy our customers’ needs.

  • High dimensional accuracy
  • Excellent production efficiency
  • Ideal for mass production
JIAHUI Die Casting Service - https://jiahuicustom.com/

What is Die Casting Process?

Die casting or pressure die casting is a technology in which liquid or semi-solid low-melting point metals are poured into the steel mold, where it solidifies into a particular metal cast after cooling. This process typically occurs at a high speed of about 0.5 to 120 m/s and high pressure ranging from 4 to 500 MPa, which makes die casting different from other casting methods. Primarily, die casting technology is known for its accuracy, versatility, repeatability, and reliability.

Regarding the working principle of this technique, the initial step is to create desired casting molds by CNC machining. Then after converting the metal alloy into the molten state in a furnace, it’s poured into the mold at high pressure. Once the metal cools and hardens, the part is ejected from the mold. Finally, the die casting part is ready for surface finishing to improve its durability, functionality, and aesthetics. Some typical surface treatments for die casting parts include powder coating, anodizing, electroplating, baking varnish, polishing, and more.

Our Qualification For Die Casting Service

With JIAHUI CUSTOM, you can enjoy the best suggestions and practical solutions regarding your die casting mold parts. We offer several tolerances, materials, and surface treatments for customers’ die cast metal products. Moreover, our expert engineers ensure the manufacturing of complex casting components with fast lead time and remarkable efficiency. Our professional management team lets customers upload die cast part design files online and allows them to track their orders at each stage of manufacturing, providing clients with high-level satisfaction.

Above all, JIAHUI follows strict quality control standards by inspecting the quality of die casting parts at different manufacturing stages, including both pre-production and in-production steps. Thus, you can trust us for outstanding quality, high-precision, and cost-effective components for die cast models of cars.

Manufacturing Process

The die casting process involves detailed design analysis and careful die-cast parts manufacturing by expert engineers. JIAHUI goes through a series of manufacturing steps to ensure the formation of high-quality products, such as designing, inspecting raw materials, production, heating, and surface treatment, reanalysis, and packaging of the products.

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Die Casting Process Categories

We offer several significant die casting processes to our customers that consistently meet their standards. Our engineers suggest the right die casting type according to the project requirements. JIAHUI’s ultimate goal is to apply either technique efficiently, so our clients may love the end products.

Hot-Chamber Die Casting Process - https://jiahuicustom.com/

Hot-Chamber Die Casting

Hot chamber die-casting involves heating the metal in a gooseneck machine, and the injection chamber and injection punch are submerged in molten metal. During this process, molten metal is present in a built-in furnace from where it’s forced into the die with the help of a hydraulic-power piston. Hot die casting suits non-ferrous alloys with low melting points, like lead and zinc.

Cold-Chamber Die Casting Process - https://jiahuicustom.com/

Cold-Chamber Die Casting

The cold chamber die-casting process is opposite to the hot chamber technique. This is because it doesn’t involve heating the metal; the injection chamber and punch are not immersed in the molten metal. Instead, the molten metal is poured into the injection chamber with the assistance of a ladle system. Then, a hydraulic piston forces the molten into the die at high pressure and solidifies it into a casting. Usually, high melting point metals such as aluminum are considered ideal for this process.

Low-Pressure Die Casting Process - https://jiahuicustom.com/

Low-Pressure Die Casting

As the name indicates, this die-casting process involves pouring the molten metal into the mold under  (around 20-100kPa)low pressure instead of gravity. The process typically initiates with melting the metal alloy, and then the melted material moves to a holding furnace below the cast. The riser tube pushes the molten metal into the die-cast, solidifying under constant pressure. The low-pressure die-casting process is considered a highly accurate die-casting technique as there’s less oxide formation and reduced porosity with fine molten metal consistency.

Vacuum Die Casting Process - https://jiahuicustom.com/

Vacuum Die Casting

Vacuum die casting is the modified form of pressure die casting that involves using a vacuum to remove air from the mold cavity before injecting molten metal. Later the molten metal is introduced into the cavity under high pressure. Solidification of the molten material in a void-free system results in enhanced mechanical properties and surface finish of the die-cast metal. That’s the reason this die-casting method is often used to manufacture high-precision castings with improved dimensional accuracy and higher mechanical strength.

Squeeze Die Casting Process - https://jiahuicustom.com/

Squeeze Die Casting

The squeeze die casting process is a combination of casting and forging processes. During this process, the molten metal is introduced to the lower half of the mold cavity, which is preheated and lubricated. A movable plunger is used to apply the additional pressure to the metal once it’s solidified to remove porosity. Squeeze die casting primarily produces high-strength magnesium and aluminum die casting parts for manufacturing industries.

Material Weight Size Limit Surface Finish Wall Thickness
Aluminum Alloy 20g-15KG 500mmx650mmx650mm Ra 3.2µm~1.6µm(0.8µm achievable if specified) 1.5mm~4mm(0.8mm achievable if specified)
Zinc Alloy 3g-3KG 200mmx300mmx300mm Ra 3.2µm~0.8µm(0.4µm achievable if specified) 1mm~3mm(0.6mm achievable if specified)
Magnesium Alloy 3g-5KG 300mmx400mmx400mm Ra 3.2µm~0.8µm(0.4µm achievable if specified) 1.5mm~4mm(0.8mm achievable if specified)
Copper Alloy 3g-3KG 200mmx300mmx300mm Ra 6.3µm 2mm~4mm(0.8mm achievable if specified)

Our Die Casting Production Capabilities

JIAHUI takes pride in producing dimensionally and geometrically complex casting products with excellent proficiency. Our vetted experts never compromise on the measurements of the parts to ensure their accuracy.

Materials for Die Casting Parts

Typically, the die casting process works with non-ferrous metals having low melting points and robust mechanical properties, such as Aluminum, magnesium, zinc, copper, lead, and more. However, sometimes ferrous and other metals may also work. Below-mentioned is some properties of these materials that help to decide the suitable material type for a certain die casting project.

  • Aluminum
  • Zinc
  • Copper
  • Magnesium

Aluminum IngotAluminum

The distinctive characteristics of aluminum make it one of the best materials for die-casting. The major aluminum alloys are A360, A380, A390, A413, ADC12, and ADC1. Among all, the A380 is the most worthwhile casting aluminum alloy.

Characteristics

  • Excellent corrosion resistance
  • Lightweight
  • High strength and hardness
  • Outstanding thermal conductivity
  • High electrical conductivity
  • Remarkable EMI and RFI shielding properties

 

ZincZinc

Zinc lead other metal materials in terms of its exceptional strength, firmness, toughness, and performance. It is preferred for manufacturing complex parts like automotive parts, housings, and die-casting meters for their better fluidity and corrosion resistance. The most common zinc alloys are Zamak 2, Zamak 3, Zamak 5, Zamak 7, ZA-8, ZA-12, and ZA-27.

Characteristics

  • Incredible mechanical properties
  • Excellent castability
  • Longer die life
  • Great surface smoothness
  • Cost-effective
  • High ductility

 

CopperCopper

Copper is a reddish-orange metal with a face-centered cubic structure that is highly valued for its aesthetics. It exhibits remarkable properties, yet, it can be alloyed with different elements, such as aluminum, tin, zinc, nickel, etc., to improve its characteristics further. The following are some fundamental properties of copper that make it ideal for producing die-casting parts.

Characteristics

  • Very soft
  • An excellent conductor of heat and electricity
  • Good corrosion resistance
  • High ductility
  • Fine malleability

 

MagnesiumMagnesium

Magnesium is another superb die-casting metal used to form several strong, lightweight alloys. Magnesium alloys typically consist of Aluminum, zinc, manganese, thorium, zirconium, and cadmium. This alloy is usually used for die-casting molds and thin-walled components without the risk of thermal cracks. Some important magnesium alloys are AZ91D, AM60B, and AS41B.

Characteristics

  • Extremely low density
  • Incredible strength-to-weight ratio
  • Good machinability
  • Low viscosity
  • Excellent fluidity
  • High corrosion resistance

 

Surface Treatment For Die Casting Parts

After manufacturing, the final step of die casting is surface finishing. Finishing aims to intensify the mechanical or chemical characteristics of the die-cast part, remove the surface defects, and enhance the physical appearance. Several types of surface treatment processes can be used for die casting parts.

Name
Product
Description
Materials
Color
Texture

Microarc Oxidation (MAO)

Micro-arc Oxidation_Magnesium Titanium Alloy Die Casting Parts - https://jiahuicustom.com/

Micro-arc Oxidation (MAO) is a surface treatment method that uses high-voltage electrical discharges to create a ceramic-like coating on metal surfaces. This process involves the formation of a dense and hard oxide layer, which enhances the material's corrosion resistance, wear resistance, and thermal stability.

Aluminum, Magnesium, Titanium

Clear, Black, Grey, Red, Blue, Gold, White, Silver, Purple

Smooth, Matte finish

Anodizing

Anodizing_Die Casting - https://jiahuicustom.com/

Anodizing improves corrosion resistance, enhancing wear and hardness and protecting the metal surface. This surface finish is widely used in mechanical parts, aircraft, die casting car parts, and precision instruments.

Aluminum, Magnesium, Titanium, Zinc

Clear, Black, Grey, Red, Blue, Gold, White, Silver, Purple

Smooth, Matte finish

Bead Blasting

Bead Blasting_Aluminum Die Casting - https://jiahuicustom.com/

Bead blasting in surface treatment is a process where fine abrasive particles, such as glass beads or ceramic media, are propelled at high speed onto a surface using compressed air. This abrasive action helps to remove rust, paint, or other contaminants, leaving behind a clean and textured surface finish.

ABS, Aluminum, Brass, Stainless Steel, Steel

Clear

Smooth, Matte finish

Powder Coating

Powder Coating_Aluminum Die Casting - https://jiahuicustom.com/

Powder coating in surface treatment is a dry finishing process where a fine powder is electrostatically applied to a surface. The coated object is then cured under heat, melting the powder particles and forming a durable, smooth, uniform coating.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Vertical stripe

Smooth, Matte finish

Electroplating

Electroplating_Die Casting - https://jiahuicustom.com/

Electroplating in surface treatment is when a metal coating is applied to a conductive surface through an electrochemical reaction. It involves immersing the object to be plated in a solution containing metal ions and using an electric current to deposit a metal layer onto the surface.

Aluminum, Magnesium, Titanium,Zinc, Copper, Stainless Steel, Steel

Clear, White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze

Smooth, Semi-matte, Matte finish

Polishing

Polishing_Surface Finishing_Die Casting - https://jiahuicustom.com/

Polishing is the process of creating a shiny and smooth surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection but can reduce diffuse reflection in some materials.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Clear

Smooth, Mirror finish

Brushing

Brushing_Light Mouting_Consumer Durables_ Die Casting - https://jiahuicustom.com/

Brushing in surface treatment refers to manually or mechanically applying abrasive brushes to a surface, usually metal, to remove imperfections, create a uniform texture, or enhance its appearance.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Clear

Smooth, Matte finish

Electrophoresis

Electrophoresis_Zinc & Aluminum Alloy Die Casting - https://jiahuicustom.com/

Electrophoresis is a process in which charged resin particles (ions) in a solution are moved by an electric field and deposited on a metal surface to form a protective coating.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Painting

Painting_Die Casting - https://jiahuicustom.com/

Painting is especially suitable for the surface of the primary material of metal. It will strengthen the material's moistureproof& rust prevention functions and enhance its compression resistance and internal structural stability.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Excellent Die Casting Services

We have hands-on experience producing top-notch die-cast parts at affordable prices.

Typical Die Casting Products

Die Casting FAQs - https://jiahuicustom.com/

FAQs Related To Die Casting

A: Advantages of Die Casting:

  1. High production rates: Die casting can produce complex shapes with high precision and consistency, making it a highly efficient process for high-volume production runs.
  2. Excellent dimensional accuracy: Die casting produces parts with very tight tolerances and accurate dimensions, making it ideal for applications where precision is critical.
  3. Good surface finish: Die-cast parts have a smooth surface finish that requires little or no additional finishing, reducing production costs and lead times.
  4. Strength and durability: Die-cast parts are strong, durable, and able to withstand high stress and pressure, making them ideal for use in various industrial and consumer applications.
  5. Material versatility: Die casting can be used with a variety of metals, including aluminum, zinc, magnesium, and copper, giving manufacturers a wide range of material options to choose from.

A: Disadvantages of Die Casting:

  1. High tooling costs: Die casting requires expensive tooling, including molds and dies, which can be costly to produce and maintain.
  2. Limited size and weight: Die casting is best suited for producing small to medium-sized parts, and making significant, heavy components can be challenging.
  3. Limited design flexibility: Die casting is a rigid process, and it can be challenging to modify the design of a part once the tooling has been created.
  4. Porosity: Die-cast parts can be prone to porosity, compromising their strength and durability if not adequately addressed.
  5. Environmental impact: The die-casting process can generate hazardous waste and emissions and have a significant environmental impact if not managed properly.

A: The materials used to make die-casting molds are typically selected based on their ability to withstand the high pressures and temperatures involved in the die-casting process. The most commonly used materials for die-casting molds are:

  1. Tool steel: Tool steel is popular for making die-casting molds because it is strong, durable, and can withstand high temperatures and pressures. It is also relatively easy to machine and can be hardened to resist wear.
  2. H13 steel: H13 steel is a type of tool steel that is specifically designed for use in high-temperature applications like die-casting. It has excellent heat resistance, toughness, and wear resistance, making it an ideal choice for die-casting molds.
  3. Aluminum: Aluminum is a lightweight and highly conductive material that can be used to make die-casting molds for smaller, less complex parts. It has good thermal conductivity, which helps to dissipate heat during the casting process.
  4. Copper: Copper is another highly conductive material that can be used to make die-casting molds. It is often used for small, high-precision parts that require excellent surface finish and dimensional accuracy.
  5. Magnesium: Magnesium is a lightweight and highly machinable material that can be used to make die-casting molds for smaller, less complex parts. It has good thermal conductivity and can withstand high temperatures, making it suitable for die-casting.

In summary, the materials used to make die-casting molds are typically selected based on their ability to withstand high temperatures and pressures, as well as their strength, durability, and machinability. Tool steel and H13 steel are the most commonly used materials, while aluminum, copper, and magnesium are used for smaller, less complex parts.

A: Several methods can be used to deal with defects such as blisters and pores on the surface of polished die-casting parts, including:

  1. Pressure Impregnation: This method involves filling the pores and blisters with a low-viscosity liquid, typically epoxy or acrylic resin, under pressure. The liquid partially fills the voids and hardens, creating a smooth, uniform surface.
  2. Thermal De-gassing: This method involves heating the die-casting parts to a high temperature, which causes the gases trapped inside the pores and blisters to expand and escape. The parts are then rapidly cooled, which helps to prevent the formation of new blisters and pores.
  3. Shot Blasting: This method involves using a high-pressure stream of abrasive particles, such as sand or glass beads, to remove the surface layer of the die-casting part. This process can remove blisters and pores and create a uniform, textured surface.
  4. Welding: This method involves filling the blisters and pores with a metal filler material, such as aluminum or zinc, using a welding process. This can be an effective method for repairing defects on the surface of die-casting parts.
  5. Chemical Etching: This method involves using an acid or alkaline solution for etching the surface of the die-casting part and removing any blisters or pores. This process can create a uniform, textured surface and improve the appearance of the part.

In summary, several methods can deal with defects, such as blisters and pores on the surface of polished die-casting parts, including pressure impregnation, thermal de-gassing, shot blasting, welding, and chemical etching. The most appropriate method will depend on the nature and severity of the defects and the application requirements.

A: Hot chamber die-casting machines are a type of die-casting machine that uses a molten metal injection system to produce high-quality metal parts. Here are some advantages and disadvantages of hot chamber die-casting machines:

Advantages:

  1. Quick production: Hot chamber die-casting machines have a fast production cycle and can produce large quantities of high-quality parts relatively quickly.
  2. High precision: These machines can produce exact and complex parts with tight tolerances, which can be challenging to achieve with other manufacturing processes.
  3. Cost-effective: Hot chamber die-casting machines can produce parts at a lower cost than other manufacturing processes, such as CNC machining or stamping, especially when producing large quantities.
  4. High production efficiency: The machines have a high production efficiency due to their fast cycle time, which helps to reduce the overall manufacturing cost.

Disadvantages:

  1. Limited to low-melting-point materials: Hot chamber die-casting machines are generally limited to materials with low melting points, such as zinc, tin, and lead. This method cannot process materials with high melting points, such as steel and titanium.
  2. The limited size of parts: The size of the parts that can be produced using hot chamber die-casting machines is limited by the size of the machine itself. Larger parts may require a different manufacturing process.
  3. High operating temperature: The molten metal used in the hot chamber die-casting process requires high operating temperatures, which can be dangerous if proper safety precautions are not taken.
  4. Short mold life: The high temperatures and pressures in the hot chamber die-casting process can cause the mold to wear out quickly, leading to increased maintenance costs.

In summary, hot chamber die-casting machines offer many advantages, such as quick production, high precision, cost-effectiveness, and high production efficiency. However, they are limited to low-melting-point materials, have a limited size of parts, require high operating temperatures, and can have a short mold life.

A: In the casting process, a molten material—such as ceramic, plastic, or metal—is poured into a mold cavity and left to solidify. The solidified material, known as the casting, is then removed from the mold and can be further processed or used as a final product.

The casting process involves several steps:

1. Pattern Creation: A pattern, typically made of wood, plastic, or metal, is created in the shape of the desired final product. The pattern may be a single piece or consist of multiple pieces that fit together to form the mold cavity.

2. Mold Preparation: A mold is made by surrounding the pattern with a molding material, such as sand, plaster, or metal. The mold material is chosen based on factors such as the material being cast, complexity of the part, and desired surface finish. The mold is designed to have a cavity that matches the shape and dimensions of the pattern.

3. Pattern Removal: Once the mold material has solidified or cured, the pattern is removed from the mold cavity, leaving behind a negative impression of the desired part.

4. Pouring: The molten material, heated to a specific temperature, is poured into the mold cavity through a gating system, which consists of channels and sprues. The gating system helps to control the flow of the molten material and minimize defects in the casting.

5. Solidification: The molten material cools and solidifies inside the mold cavity, taking the shape of the cavity. The qualities of the material, the design of the mold, and the cooling techniques used can all have an impact on the solidification process and pace of cooling.

6. Cooling and Removal: After the molten material has solidified and cooled sufficiently, the mold is opened, and the casting is removed. The casting may undergo further cooling or heat treatment processes to achieve desired material properties.

7. Finishing: The casting may require additional finishing processes, such as trimming, grinding, machining, or surface treatments, to remove any excess material, improve dimensional accuracy, and enhance the surface finish.

Casting has a number of benefits, such as the capacity to work with a variety of materials, customize, and create intricate shapes. It is commonly used in various industries, including automotive, aerospace, construction, and art, for producing components with intricate geometries or large sizes.

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