High-pressure die casting is also known as HPDC or traditional die casting. This is a unique metal casting process where molten metals like zinc, Steel, Aluminum, Lead, Copper, etc., are injected into properly created three-dimensional cavities or mold. The metal we plan on using is first melted down using extreme heat and made sure that every bit of the metal is fully transformed into its liquid state. After that, it is forced inside the mold cavity so it can take our desired shape when the mold is cooled down.
Regardless of how easy the process sounds, there is more to the method than meets the eye.
High-pressure die casting can be used to form or create various parts that we seamlessly use in our everyday lives.
This can be anything from Aerospace components or regular car engine blocks.
It is also used on everyday products like toys, gears, sink faucets, and much more.
So if you are planning to get the best high-pressure die casting service, you need first to understand what steps aluminum die casting manufacturers will take to ensure they come up with an effective outcome.
As they are unique to the high-pressure aluminum casting process, you must understand them firsthand. So without any further ado, let us dive right in.
Mold Preparation
Preparing the aluminum die casting mold is one of the most crucial parts of High pressure die casting and is the first step in this overall die casting process.
Creating the perfect mold results in a perfect yield, which should always be your end goal.
The quality of your mold preparation is the difference between having an industry-leading part of the quality and a mediocre metal part with a low-quality finish.
During this first step, the manufacturing company will use some sort of lubricant inside the interior of the mold, depending on the product requirements.
The application lubricant is extremely important as it effectively regulates the mold temperature.
Moreover, it also creates a new layer of insulation between the mold cavity and the liquid metal.
As a result, the removal process of the solid metal part becomes easier.
It also ensures that no part of the resulting tool is damaged when removed from the casting.
Injection
Once the die casting aluminum mold is fully prepared, it is time to inject it with the molten high-pressure aluminum casting we have from the furnaces.
To ensure the most effective result, molds are usually fully closed and sealed during this step.
If the molds are not completely sealed, they will not be able to control the flow of high-pressure injection of the molten metal.
Depending on various manufacturers’ techniques, product shape sizes, and metal types, the pressure can vary anywhere from 1500 PSI up to a staggering 25,000 PSI.
During this step, the mold will maintain this pressure right until the liquid metal is fully solid and ready to be taken out.
How much time it will take to cool down can also depend on the size, shape, and type of metal.
Injection to Cavity
This is the step where the aluminum die casting manufacturer fully ejects the newly formed cavity from the mold.
In most molds, there will be ejector pins that will release the cavity all by itself once it is engaged.
However, it is crucial to keep in mind to only move to this step once we are sure that the cavity is solid.
If the material used to form the part is still in its semi-liquid form, the manufacturers will wait for it to cool down further.
Shake Out
Shake is the final part of the high-pressure die casting process.
During this step, the manufacturer will slowly start separating any scrap metal from the crafted cavity.
It is very common for high-pressure die casting to make scrap metal excess to the design.
Depending on the specific design of the part you are trying to make, some extra metal will be used, which is not part of the actual design.
These excess metals can be stuck to the mold itself. To reuse the mold to make another unit, the company must remove all crap from the inside and prepare the mold from scratch again.
Advantages of Die Casting Alloy
Due to this unique high-pressure die casting process and the materials used, you will get a lot of advantages. Here are some of the noteworthy advantages:
- Great Electric Conductivity
- Improved Processing Properties of Aluminum Parts
- EMI and RFI Isolation
- Extremely High Strength and Longevity
- Corrosion Resistance in Extreme Weather
Now that we know about the basic advantages of die casting alloy, let us take a look at some of the benefits of this die casting process.
Efficiency
Once you have made one die, it can be used on multiple craft items. That means it allows you to create thousands of parts with the same specification from one single design.
Cost-Effectiveness
The second most important benefit of high-pressure die casting is its cost-effectiveness.
Due to improved speed, accuracy, and low waste of material, high-pressure die casting is one of the most cost-effective casting solutions.
More Options on Finishes
Unlike many other casting processes out there, high-pressure die casting does not necessarily focus on the finish.
That means if you have a specific finish in mind, you can customize your crafted parts according to your specific needs.
This allows businesses to add various decorative touches to the finishing.
Your aluminum die casting supplier can also enhance the chemical resistance of the parts by introducing various finishing materials to the mix.
With so many benefits the die casting process brings to the table, it is time for you to choose it over other solutions.
So what are you waiting for? Get in touch with us today to get started.
Final Thoughts
That ends today’s discussion on the 4 steps to ensuring effective high-pressure die casting.
If you want nothing but the best high-pressure die casting manufacturing, then CEX Casting has got your back.
We offer top-of-the-line aluminum die casting services to make sure you end up with nothing but the most reliable and economical solution for your specific needs.
