China Die Casting Process

China Die Casting Process

Aluminum Die Casting is a 6000 year old manufacturing process. Aluminum die Casting is a manufacturing process by which a liquid material is usually poured into a die mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Die Casting China was grow up since 1960, and rapidly grown up in recently 20 years.

Die Castings are used in areas like transportation, aerospace, defense, mining, construction, maritime, fluid power, & domestic household. Some cast components include: engine blocks, suspension parts for  auto mobiles, cooling fan components & fluid flow components like valves, pumps, pipes, and fittings. To cut the emissions there is a need to improve the fuel efficiency and make the vehicle lighter in weight. Non ferrous metal like aluminium is lighter than steel and has density one third of that of steel. Aluminium has a lower density of 2.7 gm/cc compared to 7.8 gm/cc of steel. Aluminum and aluminum alloys are lightweight with good corrosion resistance, ductility and strength. Aluminium is a light silver coloured metal placed 13 on the periodic table and is important group 3 element. It has good resistance to corrosion and due to its aesthetics it makes a suitable alloy for varied applications.
 Dr. Dinesh & Ramesh is in the process of manufacturing Aluminium die casting of various alloys including LM6, LM9, LM25, A356, 413, AlSi8Mg3, AlSi10Mg amongst others. There are various casting processes including Gravity Die Casting (Permanent Mold Casting), Low Pressure Die Casting, High Pressure Die Casting, Investment Casting, Sand Casting processes. Dr. Dinesh & Ramesh have expertise in the Gravity Die Casting and Low Pressure Die Casting processes since 1979.
In Gravity Die Casting process the metal is filled under the influence of gravity hence the name Gravity Die Casting.  The metal is carefully directed through an ingate under the influence of gravity to fill the die. There are various gates and sprues through which Aluminium enters the dies (usually made of iron alloys).There is provision of various risers to allow proper feeding and give defect free homogenous casting. It is the experience and knowledge of the foundry engineer to provide optimum risering and gating to give defect free parts. Dr. Dinesh & Ramesh has that experience and knowledge of more than 30 years to give customers value and quality. At DRE, we have always been up to speed with technology and have developed various equipments at our facility to increase productivity and sustained quality of our products to our customers.
Die Casting China Companies has also developed its own proprietary equipment for Low Pressure Die Casting. This is a relatively newer process in which metal enters into a die in a very controlled and turbulence free manner. An air tight furnace is kept underneath the metallic mold, and under air pressure (upto 25 psi – depending on the size of the casting) the liquid metal rises up from the furnace into the metallic die on top of the furnace. A very good control of the molten metal is achieved in this process resulting in reliable, pressure tight and homogenous parts. Various critical components in the industry are made through this process for eg: Engine blocks of automobiles, cyclinder heads, alloy wheels, crticial electrical components, special purpose pressure tight parts to name a few.
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Mechanical Properties of Malleable Iron

The different grades of malleable iron are essentially the result of different heat treatments. Just as a medium carbon steel can be heat treated to a wide range in properties so can malleable iron, but malleable is even more versatile. The combined carbon content, on which heat treatment depends, can be adjusted from none, as when the microstructure is entirely ferritic, to that of a fully pearlitic structure. Read more

Mechanical Properties of Cast Carbon and Low Alloy Steels

For the purpose of this article, carbon steels are considered to be those steels in which carbon is the principal alloying element. Other elements that are present and that, in general, are required to be reported are manganese, silicon, phosphorous and sulfur. In a sense, all of these elements are residuals from the raw materials used in the manufacture of the steel, although the addition of manganese is often made during the steel making process to counter the deleterious effect of sulfur and silicon is added to aid in deoxidation. Read more

White and High Alloy Irons

An important group of alloyed irons that fall outside of the ordinary types of Alloy Die castings have been designated the white and high alloy irons, or the special irons. The high alloy irons are considered separately because their alloy content exceeds 3% and they cannot be produced by ladle additions to irons of otherwise standard compositions.

The high alloy irons are usually produced in foundries that are specially equipped to produce the highly alloyed compositions. These irons are often melted in electric arc or induction furnaces, which provide for precise control of composition and temperature. The high alloy irons are sold at premium prices and are expected to outperform ordinary compositions in applications that involve severe service conditions. The foundries that produce these irons may be equipped with heat treating furnaces and quenching equipment or cooling facilities to provide for the most economical use of alloys. Read more

Mechanical Properties of Compacted Graphite Iron

    Compacted graphite iron is a fairly recent addition to the family of commercially produced aluminum casting irons. Its characteristics are intermediate to those of the gray and ductile irons. As in gray iron, the graphite in CG iron is in the form of interconnected flakes. This facilitates the production of sound castings, especially those of complex shape or with intricately cored passages. However, the relatively short span and blunted edges of CG graphite provides improved strength, some ductility, and a better machined finish than gray iron. Read more

Mechanical Properties of Cast Iron

Ductile iron is characterized by having all of its graphite occur in microscopic spheroids. Although this graphite constitutes about 10% by volume of ductile iron, its compact spherical shape minimizes the effect on mechanical properties. The graphite in commercially produced ductile iron is not always in perfect spheres. It can occur in a somewhat irregular form, but if it is still chunky as Type II in ASTM Standard A247, the properties of the iron will be similar to cast iron with spheroidal graphite. Of course, further degradation can influence mechanical properties. The shape of the graphite is established when the metal solidifies, and it cannot be changed in any way except by remelting the metal.  Read more

Tech Properties Gray Iron

  Microscopically, all gray irons contain flake graphite dispersed in a silicon-iron matrix. How much graphite is present, the length of the flakes and how they are distributed in the matrix directly influence the properties of the iron.

The basic strength and hardness of the iron is provided by the metallic matrix in which the graphite occurs. The properties of the metallic matrix can range from those of a soft, low carbon steel to those of hardened, high carbon steel. The matrix can be entirely ferrite for maximum machinability but the iron will have reduced wear resistance and strength. An entirely pearlitic matrix is characteristic of high strength gray irons, and many castings are produced with a matrix microstructure of both ferrite and pearlite to obtain intermediate hardness and strength. Alloy additions and/or heat treatment can be used to produce gray iron with very fine pearlite or with an acicular matrix structure. Read more

Aluminum Casting

The term “cast iron” designates an entire family of metals with a wide variety of properties. It is a generic term like steel which also designates a family of metals. Steels and cast irons are both primarily iron with carbon as the main alloying element. Steels contain less than 2% and usually less than 1% carbon, while all cast irons contain more than 2% carbon. About 2% is the maximum carbon content at which iron can solidify as a single phase alloy with all of the carbon in solution in austenite. Thus, the cast irons by definition solidify as heterogeneous alloys and always have more than one constituent in their microstructure. Read more