When performing high-pressure die casting, molten metals will be injected into the steel cast with the use of a hydraulic piston system. This is the most efficient method for creating complicated parts. Pressure-casting metal offers a lot of benefits which include a higher overall production output and more flexibility in its decorative, mechanical, and functional aspects.
Furthermore, high-pressure aluminum die-casting has been used by most industry professionals across the world due to its high production rates and low costs. Aluminum has been an important part of the operations methods of product designers since it is lightweight and has extreme strength.
What Does High-Pressure Die Casting Mean?
Nowadays, more and more products are becoming more complicated. Customers are requesting more detailed specifications on the shapes to keep the components last longer and more durable while reducing the materials being used. High-pressure die casting (HPDC) is more demanding since it is highly effective when it comes to producing complicated product parts.
In this method, a high-pressure die-casting machine will be used in injecting molten metal under extreme pressure into the mold cavity, also known as a die. A compressive machine will then be used for keeping the metal in place until such time that it turns solid. After the metal has solidified, it’s time to release and open the die so that the metal can be extracted.
The injection end of the die-casting machine uses pressurized gas and hydraulics when injecting the molten metal into the mold cavity at a very high speed. Also known as a shot, this injection method is capable of producing between 500 and 18,000 components per hour, depending on the application.
In fact, injecting the metal into the mold cavity only takes a fraction of a second at an amazing 3,000 to 10,000 pounds per square inch, depending on the chosen metal. The most common ones are magnesium, zinc, and aluminum. The more pressure is applied, the more the metal will be compressed into the mold cavity while eliminating any gases. Consequently, more metal will be fed to compensate for shrinkage.
What Are the Two Major Categories of High-Pressure Die-Casting?
Generally, high-pressure die casting has two main categories, which are hot chamber die casting and cold chamber die-casting.
Hot Chamber Die Casting
In this method, the molten metal will be submerged into the injection system using a hot chamber machine. The molten metal will be pumped by the piston on the nozzle, then it will travel into the die. Typically, hot chambers are ideal for metals such as zinc, magnesium, and lead.
Cold Chamber Die-Casting
When it comes to cold chamber die-casting, the molten metal will be placed inside the unheated chamber. To force the metal into the mold and get rid of the light, a hydraulic piston will be used. Among these two methods, the cold chamber die-casting method needs more pressure. The cold chamber is usually used on metals that melt at extreme temperatures including magnesium, and copper, as well as high-pressure aluminum die casting.
What Are the Benefits of High-Pressure Die-Casting?
If you use a high-pressure piston system in injecting the molten metal into the mold cavity, then there are a lot of advantages that you can obtain. The following are just some of the great benefits of using high-pressure die casting.
- Less porosity – By using high pressure, more metal will be forced into the dye, eliminating any gases and ensuring that the output is extremely durable.
- Improved production rate – By injecting the metal into the dies at a higher speed, it can help in improving the overall production rates, which can attract high-volume operations.
- Less wastage – Since the hot metal is injected directly into the dye, then there will be less scrap metal. Thousands of products can be produced before the molds will be replaced.
- Less processing operations – It can produce complicated parts with detailed dimensions and as a result, the processing operations are streamlined, eliminating any further assembling.
- Reduced environmental impact -You can recycle almost all of the materials being used in the die-casting process. Since any wastage can be recycled and reused, this method is considered a sustainable option for manufacturers.
- More profits – Since the molds can be used for producing thousands of parts before they will be replaced, this method is considered as cost-effective. With just a single mold, it has the ability to generate more complicated parts with just a single shot, reducing the essential number of components.
- Smooth finishes – By using this process, you can always assure that your component will have smooth finishes. For plating, smooth finishes are necessary, at the same time, it offers great options for electroplating treatments.
- Improved compliance with regulatory standards – Having the capability of producing complicated shapes is great for satisfying quality standards. Additionally, it permits better accommodation of tight appearance, strength, and dimensions regulations.
Best Option for Value-Added Operations
High-pressure die casting provides smooth surfaces to strong and complicated parts, however, you can also opt for value-added operations including finishing and coating options. Regardless of what is the finish requirements of your casting, there are different options for the finishes including functional, decorative, and mechanical.
This can help in preventing water damage, minimize corrosion, and improve its visual appeal. It is important that you figure out what is the most efficient finishing application for every component. The following are some of your options.
- Black oxide finishes – By using this uniform black finish, you can assure that the product can resist peeling or chipping. Consequently, it is also a great absorbent for waxes and oils, at the same time, it can resist corrosion.
- Anodizing – By using this non-conducting process, your product will be completely sealed and it comes in different colors. Furthermore, it can promote durability and resistance to corrosion.
- Chrome plating – A mirror-like, decorative finish that is commonly used in the automotive industry. Chrome plating is also an excellent option for exterior components since offers protection and looks visually appealing.
- Cobalt-tin – A cost-effective and attractive finish that can prevent wear and corrosion.
- Bright nickel – This is usually used over copper and under chrome to achieve a decorative finish. Keep in mind that this plating can be fragile, hence, it must be applied gently, in addition, this is not suitable for every application.
- Gold plating – This is commonly used for electronics applications since gold has excellent physical and chemical properties, at the same time, it does not oxidize. It might require additional cost, depending on where you apply it, however, it can be a long-term investment.
- Robotic finishing – This process uses robots in sanding and polishing the surface of your product, providing you with a brilliant, smooth, and natural finish.
- Silver plating – Silver is solderable, ductile, extremely malleable, and decorative. Furthermore, silver has the highest electrical and thermal connectivity but at the same time, it can also get tarnished once they are exposed to elements.
Due to the numerous options that are available, it is highly recommended that you should consult a professional to help you in determining the most suitable for you.
SEI Castings can help you with your casting needs. We manufacture custom and standard aluminum die-cast products with utmost accuracy and quality. We can help you in designing and produce your custom parts that are customized based on your needs and projects. If you want to learn more about our products, then do not hesitate to call us at firstname.lastname@example.org.