Aluminium Casting

A Basic Guide to Choosing Aluminum Casting Alloys Part 2

Alloys 319.0, A319.0, B319.0 & 320.0
Alloys 319.0 and A319.0 exhibit very good castability, weldability, pressure tightness and moderate strength. They are very stable alloys (i.e., their good casting and mechanical properties are not affected seriously by fluctuations in the impurity content). Alloys B319.0 and 320.0 show higher strength and hardness than 319.0 and A319.0 and are generally used with the permanent mold casting process. Characteristics other than strength and hardness are similar to those of 319.0 and A319.0. Read more

Get feel and appearance of the standard with die casting

Die casting has gained significance in the industries where precision is a matter of worry. While ensuring customers with a full finish in products, this die casting process has become a prime option for the users. Its advent in manufacturing and big industrial units has increased their productivity and performance by all means. This technique is used to mold and produce the product with the best finish. Usually made from non-ferrous metals, like copper, zinc, magnesium, aluminum, pewter, lead, and tin-based alloys, it is characterized by forcing molten metal under top force into a mold cavity. They are relatively easy to process and curtail high expenditure. Suited for a big quantity of little medium casting, they maintain dimension consistency.

Die casting gives parts that are durable and dimensionally stable in nature. While providing hard shapes of industrial parts within closer tolerances, it decreases or eliminates secondary machining operations. Die-cast parts have bigger resistance to temperature extremes. Marked as one of the quickest and most affordable techniques for producing a big range of components, it has become the most commended force of the metal industry. Being important to many manufacturing industries like hardware, white goods, automotive, electronics and electrical and many others it provides components in zinc, aluminum, and zinc alloys efficiently, rightly with best mechanical features and consumer appeal.

Die casting has located a powerful emphasis on the application of scientific knowledge to its producers. The integrated process is important for producing engineered products that make sure long term advantage. It manufactures parts with thinner walls, marked with closer dimensional limits and perfect surfaces. With the advancement of the auto industry and the rise in trade, demand for casted parts has taken a big hike. This process can be carried out either by using the hot or cold chamber. Zinc casting is considered to be the most perfect way by gathering the precision with physical and excellent properties of zinc. With aluminium die casting it becomes simple to avail meticulous parts in high volume at low costs.

With consistent standard over high volume, it makes sure the long life of the die mold. Tested and certified by experts, casting parts to mark their brilliance in all endeavors. If you are seeking these parts, you can forever take the help of internet stores or can avail of their services through other sources. But before you go for them, ensure that you are availed with best knowledge and top advises, so that you can meet your specific needs.

Injection molds taking benefit of a global industry

The world of manufacturing has become and more hard over the years. If you are in this industry, then you probably already have a sense of this issue. What has been happening in the international market place has truly started to live up its name. whereas a few years ago there were a handful of outsourcing firms in a select number of countries, nowadays, it is impossible to keep track of production. When you look at an industry such as injection molds, you can view this trend truly taking off. While it may be overwhelming at first, anyway, you will no doubt find that it makes production more affordable. Plastic molding has become much more successful with a more quickly turnaround.

Injection molding parts
Injection molding parts

If you have been looking for an injection molds company to perform your work, you are going to want to keep a few things in mind. You have to ask yourself what it is you are looking for in a top plastic molding firm. You want precision. This should go without saying. You want to get actually the work that you ordered. When you considered the demands located on you in a competitive industry, you will realize that you also need punctuality. Punctuality might not even be powerful enough for them. What you need is a quick turnaround. The sooner you obtain the plastic injection molding parts you have ordered, the sooner you will be capable to finish the production on your end. Finally, you want to view best cost-effectiveness.

Keep these things in mind, you should be capable to make a general sense decision about the top plastic molds service to you. What you need is a plastic molding company that will know the benefits of working on an international scale. This is a firm that will send the plastic work wherever it needs to be sent. This means that if the injection tooling needs to be performed in China, but the assembly and finish requires to be done in Mexico, the top firm will send your parts to these countries. What is most vital in cost and speed.

Also bear in mind that when you find the best global injection molds company, they are going to be familiar with working with international clients. This means that you can have your plastic molds sent to any place on the planet. The top service expects its customers to have offices in a number of different countries, so they will go out of their way to make your order get done rightly and shipped to any place fast.

Aluminum Casting Construction Metal Parts

Aluminum Casting Construction Metal Parts Description:

Construction part:
1, accurate in reading drawings

item nameconstruction part
Material stainless steel, zinc, aluminum, casting, forged, brass, etc.
Material gradeGB, ASTM, AISI, DIN, BS, JIS
ProcessingMachining, casting, forging, welding, surface treatment
MOQ300 pieces
Supply ability90 tons per month
PaymentT/T&L/C
Related productsStainless steel casting, sand casting, die casting, valves, fittings, 
bronze & brass alloy, zinc alloy, bearings, gearings
IntroductionOur factory is located in Dongguan which is one of the biggest port city in China. We are experienced in producing all kinds
 of metal parts. You can get products good in quality and 
competitive in price from us. The win-win situation is our goal.
 Good relationships can always be kept between foreign 
customers and us. If you are interested in our products, don¡¯t 
hesitate to contact us.

2, experienced in manufacturing
3, fast in delivery
4, low price

Primary Competitive Advantages:

– Quick Response on Inquiry 

– Protective Packaging 

– Prompt Delivery 

Main Export Markets:

– Eastern Europe 

– North America 

– Mid-East/Africa 

– Asia 

– Western Europe 

Die Casting Design

Die-casting can be done using a cold chamber or hot chamber process.

1. In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures.

2. In a hot chamber process, the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures. die casting, aluminum die casting, aluminum casting, ADC-12 die casting, automotive die casting part, motorcycles spare part, aluminum pressure die casting

Automotive die casting
Automotive die casting

3. Die casting molds (called dies in the industry) tend to be expensive as they are made from hardened steel-also the cycle time for building these tend to belong. Also, the stronger and harder metals such as iron and steel cannot be die-cast

Aluminum die casting process introduction

Though the term die casting can refer to any kind of casting using a die such as gravity die casting or low pressure die casting, yet here die casting only refer to high pressure die casting. Aluminum die casting is a process of casting Aluminum alloy under pressure, can produce precision parts in high volume at low costs. There are two processes of aluminum die-casting namely hot chamber die casting and cold chamber die casting. Parison die casting introduced cold chamber die casting process from1980’s. Now the die casting machines which Parison die casting is applying are cold chamber die casting machines.

Illustration of cold chamber die casting process

In a cold chamber die casting process, the molten aluminum alloy is ladled into the cold chamber for each shot. There is less time exposure of the melted alloy to the plunger walls or the plunger. This is particularly useful for aluminum alloy that alloys easily with Iron at the higher temperatures.

After the molten aluminum alloy is ladled into the cold chamber, the piston will inject it into the cavity of the die casting mold through three different pressure phrases. The pressured molten aluminum alloy gets in sequence through spure system, running system, and gate system into the cavity of the die casting mold.

The filled cavity with affection of cooling system shapes the desired aluminum die casting products. Then the moving die moves away from the fix die, while the ejectors push out the casting.

Advantage of aluminum die casting process

A.high volume but low cost Compared with aluminum sand casting and gravity casting, aluminum die casting can produce precision parts in high volume at low costs.

Aluminium die casting
Aluminium die casting

B.good surface finish and good dimensional accuracy Aluminum die casting generally has good surface finish and good dimensional accuracy. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.

The disadvantage of aluminum die casting process

A.high cost of die casting mold The cost of tooling of die casting is much more expensive than those of sand casting, gravity casting, and investment casting.

B.high porosity Though the porosity of die casting can be adjusted by using much higher pressure with a much larger and heavier mold, the porosity can not be avoided and is much more than that is of low-pressure casting and gravity casting. Furthermore, porosity leads die casting parts to be not suitable for heat treatment. Thus the consistency can not be compared with gravity castings.

FAQ’s of aluminum die casting process

what is aluminum die casting process?

what is the cold chamber die casting process?

what is the difference between cold chamber and hot chamber die casting process?

What is the application of die casting process?

what kinds of metal can be applied in die casting process?

why is the cold chamber die casting process preferable for aluminum casting rather than hot chamber die casting process?

what is the application of die casting products?

what kinds of post-treatments can be available for aluminum die casting products?

what is the difference between aluminum high-pressure die casting and low pressure die casting?

what is gravity die casting? Is it the same as high pressure die casting process?

Aluminum Casting Powder Coating

Aluminum Casting Powder Coating Description:

About Aluminum die casting product

 Process 1) Material: Aluminum alloy, A360, A380, ADC 10, ADC 12, ZL102, ZL1042) Machining: CNC turning, milling, drilling, grinding, cutting, reaming and threading3)Plating: In house polishing, brushing, chrome plating, nickel plating, gold plating
Surface treatmentElectro-polish, Chrome plating, Sandblasting, Painting, Powder coating, Electrophoresis, Anodizing etc
ApplicationAuto parts, motor shell, pump parts, machinery parts etc
Applied softwarePro/E, Auto CAD 2000, solid work 2001,CAXA,UG,CAD,CAM

Alloy Die Casting

Alloy Die Casting Description:

Aluminum Alloy Die Casting A380 is the most common of the aluminum die casting alloys. It offers the best combination of casting and product properties. It is used for a wide variety of products such as garden equipment, chassis for electronic equipment, engine brackets, housings for automotive alternators, starters and water pumps, home appliances, furniture, office equipment hand tools, and power tools. Alloys 383 and 384 are alternatives to 380 that are specified when very intricate components require improved die filling characteristics and improved resistance to hot cracking. Alloy 360 offers high corrosion resistance and superior strength at elevated temperatures than 380. Other properties are essentially equivalent. Alloy 413 offers the best die fill characteristics making it excellent for pressure tightness applications. it is the choice for products such as hydraulic cylinders and pressure vessels. Its casting characteristics make it useful for very intricate components.

aluminum die casting
aluminum die casting

Alloy 390 was developed for automotive engine blocks. Resistance to wear is excellent, but ductility is the lowest of the die casting alloys, with elongation less than 1%. Special surface treatment systems allow engine pistons to run directly on the alloy surface, eliminating the need for ferrous alloy liners. It can also be used for valve bodies and bearing surfaces subject to abrasion and wear.

Alloy 518 is used in escalator components, conveyor components, and marine and aircraft applications It offers good ductility and very good corrosion resistance. It can be polished and anodized for a decorative finish. Zinc Alloy Die Casting Zinc alloys are versatile, cost-effective materials which can be used in a diverse range of die casting applications. As precisely formulated metal alloys, they offer the mechanical properties of medium strength metals. Advantages of Zinc Alloy Die Casting Overall, zinc alloys have significant advantages as casting materials for small components, with excellent physical and mechanical properties, castability and finishing characteristics. Hot chamber die-cast zinc alloys can be cast to tight tolerances, complex detail, net shape, and the alloy¡¯s dimensional stability ensure part-to-part consistency over long production runs. Net shape manufacturing is one of the main advantages of hot chamber die-cast zinc alloys.

The most commonly used zinc alloys are ZAMAK™ 2, ZAMAK™ 3, ZAMAK™ 5, Acuzinc. These alloy families offer higher tensile strengths than most aluminum and magnesium alloys, higher yield strengths, greater impact resistance, higher Brinell hardness, and better ductility. ¡¡è Zinc alloys facilitate higher die casting cycle speeds versus aluminum and other metal alloys, more complex shapes, thinner sections, smoother surface finishes, surface finishes, and higher standards of dimensional accuracy. Compared to plastic, zinc alloys are several times stronger and many times more rigid. Their mechanical properties compare favorably with powdered iron, brass, and screw-machined steel. Zinc has inherent EMI/RFI shielding properties.

CNMCast uses only high-grade zinc alloys certified for purity. Although these materials are completely recyclable, scrap is never re-melted or re-used within our process. Zamak 3 die casting is the standard for the Zamak series of zinc alloys; all other zinc alloys are compared to this. Zamak 3 has the base composition for the Zamak alloys (96% zinc, 4% aluminum). It has excellent castability and long term dimensional stability. More than 70% of all North American zinc die castings are made from Zamak 3. ZAMAK #5 offers high tensile strength, hardness, and creep resistance than zamak# 3, and somewhat lower ductility.

It is preferred whenever these properties are required. Some die casters use only zamak# 5, which is usually an acceptable alternative to zamak# 3. ZAMAK #7 is essentially a high purity form of zamak# 3 with slightly higher ductility and lower hardness. The other mechanical properties are identical to zamak# 3.

The alloy also exhibits higher fluidity than zamak# 3 or3 5, which theoretically allows slightly thinner walls. Zamak# 7 may be specified when high ductility is required. ZA-8 is rapidly growing in popularity for pressure die casting.

ZA-8 can be cast in hot chamber die casting machines for fast cycle rates, It has improved strength, hardness and creeps properties over the ZAMAK alloys with the exception of a No. 2 alloy which is very similar in performance. ZA-8 is readily plated and finished using standard procedures for ZAMAK. When the performance of Zamak No. 3 or No. 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.

Zamak 5 die casting
Zamak 5 die casting

ZA-12 is also a good pressure die casting alloy, using the cold chamber process, which provides a sounder structure than ZA-27, as well as higher die-cast elongation and impact properties. For these reasons, die-cast ZA-12 often competes with ZA-27 for strength application. An excellent bearing alloy, ZA-12 is also platable, although plating adhesion is reduced compared to the ZAMAK alloys. ZA-27 is the high strength performer of the zinc alloys and is die-cast using the cold chamber process.

It is also the lightest alloy and offers excellent bearing and wear resistance properties. ZA-27, however, requires care during melting and casting to assure sound internal structure, particularly for heavy wall sections. It may also need stabilization heat treatment when tight dimensional tolerances are required. ZA-27 is not recommended for plating. However, when brute strength or wear-resistant properties are needed, ZA-27 has demonstrated extraordinary performance.

Aluminum sand casting

Aluminum sand casting Description:

Aluminum Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy. Because the sand mold must be destroyed in order to remove the part, called the casting, sand casting typically has a low production rate. The sand casting process involves the use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The sand mold separates along a parting line and the solidified casting can be removed. The steps in this process are described in greater detail in the next section.

Mininum of Quantity 100 Piece/Pieces
 Unit Weight 50g~50kg
 Packing Details  Paper Box in Wooden Pallet
 Delivery Time One month
 Payment Terms L/C, T/T
 Machining CNC
 Supply Capacity 50 Metric Tons per Month
 Standard DIN,ASTM,GOST,BS

GC mold is Sand casting China company, offer the die casting service, sand casting is the most widely used casting process, utilizes expendable sand molds 

to form complex metal parts that can be made of nearly any alloy. Because the sand mold must be destroyed in order to remove the part, called the casting, sand casting typically has a low production rate. The sand casting process involves the use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The sand mold separates along a parting line and the solidified casting can be removed. The steps in this process are described in greater detail in the next section.

Shell Moulding produces castings with close dimensional tolerances, good surface finish and excellent reproduction of detail. The process often reduces the amount of subsequent machining, assembly, and finishing when compared to conventional moulding.

Die Casting Technology

What is die casting?

Die casting is a casting liquid die forging method. Die casting die forging process is a kind of special casting forging machine to accomplish the process. Its basic technological process is: first metal liquid in low or high-speed casting filling into the mold cavity, die with a moveable type cavity surface, it with the liquid metal cooling process pressure forging blank, both the elimination of shrinkage defects, also make the rough internal Aluminum Die Casting organization to forge the broken crystal. Rough comprehensive mechanical properties are improved significantly.

Aluminum die casting is a method of using high pressure forced the molten metal into complex shapes of hydraulic die within a precision casting method. In 1964, Japan Die Casting Association for die casting is defined as” in the high temperature melting alloy pressing precision molds, in a short time a large number of production of high precision and excellent casting surface”.

The United States said casting for Aluminum die Casting, the UK Pressure Die Casting is called die casting, and the most common domestic industry are familiar with is the Japanese version, called die casting. Through the method of die casting produced in the casting, is called die casting ( Die-castings ).

This material tensile strength, compared to ordinary casting alloy high nearly doubled, for aluminum alloy automobile wheels, frame and hope to use more high strength and impact resistant material production parts, have more positive significance.

New material of aluminum-lithium alloy

Yesterday, reporter learned from Shanghai Academy of Spaceflight Technology, the hospital in Temple One goal of the task assumed aircraft cabin structure and assembly of resources, power sub-systems, docking mechanism subsystem, control and communication subsystems supporting stand-alone subsystems and overall circuit Resource module cable network research task.

Resource tank “fuel” an increase in total weight was reduced by 10%

Temple One of the energy as a source of resources and power module, and the JEM to be connected with the launch vehicle, in addition to ensuring a reliable connection, the cabin is also equipped with a number of subsystems within and outside the nearly 200 sets of equipment and a large pipe, cable and so on. The structure of the resource module design, installation and testing have brought a lot of problems. Development process with a large number of new technologies, new processes.

Designed from the start, the resource module is facing, “weight” problem. Because the resources to carry propellant tank before the Shenzhou spacecraft than an increase of 50% or more, but the construction of the main cabin still hope for the implementation of weight loss. In this way, before the use of aluminum is difficult to meet the requirements, the first use of aluminum-lithium alloy as the raw material, 10% of successful weight loss for the cabin.

In order to maintain long-term in-orbit requirements of the target aircraft, the entire device carried by the lofty air and oxygen-carrying capacity of a single spacecraft, for environmental control and life support sub-system uses a large-capacity high-pressure composite cylinder for gas storage. It is reported that the inflatable cylinders before and after the change in the direction of larger diameter, the resource module assembly with a certain flexibility in design of cylinders installed bands, difficult to install to solve the problem of the cylinder, greatly reducing the weight of the cylinder mounting bracket for the entire device contributed to weight loss. Aluminum Casting Heat sink parts

Power solar “wings” using new technology

For manned space flight, the aircraft power subsystem has always been the lifeline.

This time, Temple One pressure on the semi-rigid solar wing, the technology of China’s first spacecraft power subsystem applications. Externally, two solar wings like a pair of “wings” covered with horizontal black solar film, artful. The face of low-orbit space station environment, before the full use of high-orbiting satellites are obviously not applicable to rigid panels. After a number of technology experiments, researchers identified the Shanghai grid panels with fiberglass glue and glue concentration in the actual operation and other parameters to determine the carbon-fiber frame with glass fiber mesh of semi-rigid structure.

Butt has gone through 16 years of R & D away

For eight and Temple of God “space Kiss”, Shanghai Academy of Spaceflight Technology 805 development team started from 1995, Principles of docking technology, simulation to explore, to create in 1999 a first prototype of 1:1, from 2000, ten key technology component-level research, developed in 2002 for engineering applications of docking mechanism and the four large-scale research prototype system-level ground simulation test equipment, docking mechanism 2005, sub-systems from the official project to be completed in December 2009 initial research into the positive kind of work, completed in November 2010 is kind of product development to deliver, to the range of 2011 to the base test, the 16-year road to product development from scratch, Aluminum Casting Anodized from there to fine, docking points The journey continues … the system … 

The characteristic of die casting

High Pressure die casting or gravity casting, is a molten gold poured into the pressure chamber, to the high speed filling steel mold cavity, and the alloy liquid under pressure solidification and casting method. Die casting is distinguished from other casting method is mainly characterized by the high pressure and high speed. The metal liquid is under pressure to fill the cavity, and at higher pressure solidification under common pressure, 15 to 100MPa. The liquid metal to the high speed filling cavity, usually in the 10 – 50 meters / second, some still can exceed 80 m / s, ( through the gate into the cavity of the line speed gate speed ), thus the filling time is very short, about 0.01 – 0.2 seconds ( must be considered casting size different ) can fill the cavity. Die casting machine, die casting alloy and die casting is a casting production of the three elements, are indispensable.

die casting process is called the three major elements of organic ground be used, enabling stable rhythmically and efficient production of appearance, inherent quality good, size consistent with patterns or the agreement in accordance with the requirements of qualified casting, even high-quality casting. Die casting is a kind of precision casting method, through casting and metal die-casting dimension tolerance is very small, the surface accuracy is very high, in most cases, die castings without further machining to assembly application, threaded parts can also be directly cast.

From the general photography, typing machine, mechanical computing devices and accessories and other small parts, as well as the automobile, locomotive, aircraft and other means of transport complex parts using mostly die casting manufacturing.

Die casting method also has the following shortcomings:

( 1) Die Casting Alloy is restricted at present only zinc, tin, lead, copper, magnesium, aluminum and other six kinds of copper alloy, with the highest melting point. Recently there have been reports of cast iron casting, but for the sake of economic factor, must be related to the research of materials, mold materials and operation method.  
( 2 ) expensive facilities needed equipment such as the production of the die casting machine, melting furnace, holding furnace and casting mold costs are quite expensive. 
( 3) the casting of poor airtightness due to melting liquid by high-speed filling to die when, can produce turbulence phenomenon, the local formation of a stoma or shrinkage, influence the airtightness of castings. There is currently an IMPREGNATION processing method, can be used to improve the resistance to airtightness.