Pressure Die Casting
Pressure Die Casting is a high-precision manufacturing process used to create complex metal parts with tight tolerances and excellent surface finishes. The process involves injecting molten metal into a steel mold under high pressure, allowing it to solidify into the desired shape. Pressure die casting is widely used in industries requiring mass production of high-quality metal components, such as automotive, electronics, and home appliances.
High Pressure Die Casting (HPDC)
This method involves injecting molten metal into the mold cavity at very high pressure, typically above 1000 bar. It is ideal for creating thin-walled and complex-shaped parts with high dimensional accuracy.
Low Pressure Die Casting (LPDC)
LPDC uses lower pressure (typically 2-5 bar) to slowly fill the mold from the bottom. This method is suitable for larger parts that require a smooth, uniform structure, such as wheels and large housing components.
Available Materials For Pressure Die Casting
Here is the list of available metals for pressure die casting. If you need any customized materials, please get in touch with us.
Available Surface Finishes For Sheet Metal
Die-cast components can undergo a variety of surface finishes to enhance their appearance, corrosion resistance, and mechanical properties. Below are the most common surface finishes for pressure die-cast parts
| Materials | Process | Features |
|---|---|---|
| Aluminum Alloys | Both | High strength-to-weight ratio; Excellent corrosion resistance;Thermal conductivity: 150-250 W/m·K ; Electrical conductivity: ~37% IACS |
| Zinc Alloys | High Pressure | Superior fluidity, ideal for complex structures; Low melting point (~380°C), longer mold life; Excellent dimensional accuracy; Surface finish: Ra 0.4-1.6 µm |
| Magnesium Alloys | High Pressure | High strength, good rigidity; Excellent vibration damping properties; Melting point: ~650°C; Thermal conductivity: 76 W/m·K |
| Copper Alloys | High pressure | High strength and wear resistance; Electrical conductivity: 80-90% IACS; Thermal conductivity: ~380 W/m·K; Superior corrosion resistance |
| Cast Iron | Low pressure | High hardness and strength; Excellent high-temperature resistance; Melting point: ~1200-1300°C; Wear-resistant properties |
Tolerances For Pressure Die Casting
| Features | Tolerances |
|---|---|
| Linear Dimensions | ±0.05 mm to ±0.15 mm (per 25 mm) |
| Flatness | ±0.08 mm to ±0.2 mm |
| Straightness | ± 0.010” (0.254mm) |
| Position | ±0.1 mm to ±0.3 mm |
| Surface Finish | Features | Applications |
|---|---|---|
| Powder Coating | Electrostatically applies a dry powder, which is cured under heat to form a tough, uniform coating. | Automotive parts, electronic housings, outdoor components |
| Anodizing | Electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant anodic oxide finish. | Electronics, consumer products, automotive trims |
| Electroplating | Uses an electric current to deposit a metal coating (e.g., zinc, chrome, nickel) onto the part’s surface. | Electrical connectors, automotive trims |
| Machining (CNC) | Precision cutting and shaping of critical surfaces to improve tolerance and fit. | Mating parts, high-precision assemblies |
| Polishing | Mechanical polishing to achieve a mirror-like or reflective surface. | Decorative parts, visible components |
| As-Cast Finish | The part is left in its original, unprocessed state after casting. Slight texture due to mold surface.. | Internal components, non-visible parts |
Gallery Of Pressure Die Cast Parts
Specialist Industries
We have manufactured millions of parts for various applications, with particular expertise in the following areas.
Automotive
Create lightweight, high-strength components with complex geometries, to enhance vehicle performance and fuel efficiency
Consumer Electronics
Manufacture parts requiring highly cosmetic features for smart phone, gaming, audio, video and so on.
Home Appliances
Enables the production of precise, durable, and visually appealing parts to ensure excellent surface finish and dimensional accuracy
FAQ
MOST FREQUENT QUESTIONS AND ANSWERSQ1: What materials can be used in pressure die casting?
A1: Common materials include aluminum, zinc, magnesium, and copper alloys, chosen for their properties like strength, lightweight, and corrosion resistance.
Q2: What is the difference between high pressure and low pressure die casting?
A2: High pressure die casting uses high force to inject molten metal into the mold, suitable for thin-walled parts, while low pressure die casting uses lower pressure, ideal for producing larger parts with uniform structures.
Q3: What are the typical tolerances for pressure die casting?
A3: Tolerances can range from ±0.05 mm to ±0.15 mm for linear dimensions, depending on the part’s geometry and material.
Q4: What surface finishes are available for die-cast parts?
A4: Common finishes include powder coating, anodizing, electroplating, painting, and polishing, enhancing appearance, corrosion resistance, and mechanical properties
Q5: How complex can die-cast parts be?
A5: Pressure die casting is ideal for producing intricate shapes with complex geometries, thin walls, and tight tolerances that would be difficult to achieve with other processes.
Q6: How long does a pressure die casting mold last?
A6: Mold lifespan depends on the alloy and production volume. On average, a mold can produce between 50,000 to 100,000 cycles for zinc and 100,000 to 200,000 cycles for aluminum.
Q7: What are the advantages of using pressure die casting?
A7: It offers high production efficiency, excellent dimensional accuracy, smooth surface finishes, and the ability to create complex shapes in a single process.
Q8:Can pressure die casting achieve tight tolerances?
A8: Yes, it can produce parts with high dimensional accuracy, typically achieving tolerances within ±0.1 mm for most applications.
Q9: What are the common defects in pressure die casting?
A9: Typical defects include porosity, shrinkage, and misalignment, but can be minimized through process optimization, quality control, and proper mold design.