2022-03-18
High pressure die casting (HPDC) is a process whereby, molten metal or metal alloy is injected at a very high speed and pressure into the mold. It is also referred to as traditional die casting. This is a metal casting process that involves injecting molten metal (Mg, Zn, Pb, Cu- alloys) into a 3D mold. The base metal is extremely heated until it assumes a liquid, molten state. It’s then forced into the mold cavity, making it take the shape of the mold once it solidifies.
While there are different ways to perform the process High pressure die casting. Most of the ways involve four steps.
During this initial step in High pressure die casting, we apply a lubricant to the interior walls of the mold. The lubricant is meant to regulate the mold’s temperature, creating a film between the molten metal and the mold, hence the easier release of the casting.
After preparation of the die mold, it is injected with molten metal. In this step, the molten metal is forced, under high pressure, into a sealed and enclosed mold cavity. The cavity has got a powerful compressive power which holds the molten metal in place until it solidifies. It is normally closed and sealed to ensure the mold maintains the high pressure until the molten metal gets cooled and solidifies. Injection of the molten metal into the mold cavity takes place in a fraction of a second (usually under 100 ms).
In this step, the manufacturing company releases the newly made cavity from the mold. The mold features ejector pins that, when engaged, eject the cavity. Well, the cavity must have solidified for it to eject. And if the raw metal is still liquid, the company ought to wait for it to cool before it can release the cavity from the mold.
During this final step, the manufacturer separates any scrap metals from the newly created cavity because not all of the molten metal is used up while creating the casting .although High pressure die casting does not produce excess scrap metal. Some metals remain stuck on the walls of the mold so then, every scrap metal must be removed before reusing the mold.
The selection of a particular chamber system depends on the metal being used. To inject molten metal into the mold, two different systems may be used which are; a hot chamber system and a cold chamber system.
This system is used with metals like zinc, magnesium, and lead. In this system of injection, the metal is held within the diecasting machine itself and then forcefully immersed in molten metal from the blast furnace using a piston pump.
This injection system is used for metals with high melting temperatures, such as aluminum and copper. In this process, the metal is first melted separately in a furnace, transferred to a holding furnace, and then injected into the mold. A hydraulically activated piston moves down this channel while pushing the metal into the mold.it then cools and solidifies. After the flow solidifies, the piston is pulled back, and the mold is opened, the flow is released.
This process of die casting realizes higher production speeds when compared to the flow pouring under gravity.
Ensures production of flows of specific dimensions which directly reduces processing operations.
Good surface finishes for the fusions, which is a basic requirement for plating.
The results are durable molds, thus reducing unit cost prices.
It can be used to manufacture more complex parts, thus decreasing the number of components requested each time.
During the period of our experience, Best Precision Co.Ltd has specialized in ensuring high-level high pressure die casting processes. These are made available through our vast knowledgeable team and by leading-edge technology.
The initial step of this process is all about analysis of Fluid dynamics and Thermal properties, vital for optimizing the whole process and ensuring high-quality production. Clear Simulation and virtualization while developing molds are vital steps and they are created by a Best Precision Co.Ltd dedicated division.
These high-quality productions are directly coupled with high hygiene alloy process with perfect degassing systems, global thermal control processes, and effective temperature and pressure sensors.
This process is widely used in the automotive/ automobile industry. Cold chamber high pressure die casting technology is the most ideal for this application. The auto motive’s aluminum parts can be produced through aluminum injection under high pressure and temperatures. For this common application, at Best Precision Co.Ltd Company, we have a complete line of standardized products, steel tools, and newly developed steels to quench your thirst for the search of your specific applications.
These new tech tools which are wide of aluminum and magnesium automotive castings include the engine blocks, gearbox casings, oil sumps, engine mounts, and other high-strength structural automotive and aeroscope components as well as various consumer goods.
In the past, die casting was most suited to softer alloys. The popularly used materials in the die-cast parts are tin and lead. Today, zinc, aluminum, and magnesium-based alloys have become most commonly used in the die casting processes.
If you finally decide that high pressure die casting is the right process to suit your final application, you will have to get a reliable producer for those components. This is why you should choose us.
Firstly, we mitigate the restriction about the limitation on the surface area and weight by using high pressure die casting machines with locking forces of ≈ 200 to ≈500 tones.
Secondly, all of our machines have computerized real-time shot control, automated ladling, die-spray techniques, the automated casting extraction process, and cooling. This advantage rewards excellent repeatability and productivity.
In recent years, Best Precision Co.Ltd has implemented the High pressure die casting process with great success and has positively impacted the telecom and automotive markets. These implementations have led to the emergence of vacuum die casting, semisolid casting, and squeeze casting processes.
Once we have the die casting at hand, we begin secondary processing. We have reliable suppliers experienced in quality die casting. Working with us means you don't have to source parts from suppliers, we have everything ready. To understand more about our capabilities and processes, get in touch today!
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