The aluminum die casting process allows for achievement of maximum economic effect when it is compared to other types of aluminium casting. This is applicable for products requiring high dimensional accuracy and minimal machining in the future.

We have experience in manufacturing products using the high pressure die casting method with a weight ranging from 0.04 kg to 8 kg (weight of the poured aluminum of up to 11 kg).

Aluminium die casting involving application of special tools.
Casting mold transferred to us by the client, or manufactured at the client’s cost are the property of the client. We are therefore held liable for their safe keeping and operability. Within this responsibility, we may provide accident insurance for casting mold, if the client so wishes. To extend the lifecycle of the casting mold and ensure quality of the products manufactured, thermostats are applied to ensure the predetermined temperature range of the casting mold.

Our personnel provide maintenance of the casting tools in the course of order fulfillment, as well as provide for any required repair. Medium up to major repairs are agreed upon with the owner of the tools ahead of time.
To control the use of the resource of casting tools, we take account of the actual volume of output and record it in the tool data sheet. If so requested by the client, we will provide a quarterly report on the use of the casting tools for the current period.

Casting:
Design of the tools, their size and requirements for a specific detail determine the size of the casting machine we use for aluminium die casting. We have casting machines in place from 630 to 1,000 tons. The actual die casting products output depends on the design and condition of the casting tools, as well as the complexity and weight of the product – we have experience in product output of up to 240 die casting products per hour.

The casting machine for aluminium die casting, model 711A12 (closing force is 10000 kN)

The casting machine for aluminium die casting, model 711A12 (closing force is 10000 kN)

For each die casting products, casting charts are developed. These are entered into the control computer of the casting machine and controlled by the process engineer on a real time basis. We employ the FMEA method for the purposes of any failure type and its cause analysis.

Fettling:
After aluminium die casting, flow gates are fettled for the purpose of further processing, and the die casting products are supplied for subsequent aluminium machining operations according to the process flow chart: finish machining (turbine shot-blasting machine, machine trimming) or CNC machining.
High pressure die casting is oriented towards manufacture of large product lots; however we can supply medium and small product lots in order to meet the interests of our clients.

Reference

Aluminium die casting is a method of manufacturing castings, in which an alloy becomes the form of castings, is quickly filling in the mold. Alloy at high pressure from 7 to 700 MPa is formed into the desired shape. This method is applied to non-ferrous metals (zinc, lead, aluminium, copper, magnesium, an alloy of Sn-Pb) because of their low melting points, and also for some steels. Products can be weight from tens of grams to tens of kilograms.For aluminium die casting applies high pressure die casting with casting machines with a cold chamber die (mainly aluminium casting) and die casting at a relatively low pressure casting machines with hot chamber die (both as a rule of this zinc casting).

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The casting machine for aluminium die casting, model 711A11 (closing force is 8000 kN)

The casting machine for aluminium die casting, model 711A11 (closing force is 8000 kN)

For aluminium die casting applied casting machines with cold chamber die and mold injection molding. In mold injection molding filling chamber is separate from the cavity and its material before filling the mold completely closed. The molten aluminum alloy is supplied from the load chamber into the mold cavity through a runner hole (channels). Molds injection molding performed with the top or bottom of the loading chamber.

This class of molds used for the mass production of products of any complexity. The components of the mold and the necessary characteristics for aluminium die casting:

Die component

Material

Hardness

Cavity inserts H13 42–48 HRC
H11 42–48 HRC
Cores H13 44–48 HRC
DIN 1.2367 42–48 HRC
Core pins DIN 1.2367 prehard 37–40 HRC
Sprue parts H13 46–48 HRC
DIN 1.2367 44–46 HRC
Nozzle H13 42–48 HRC
Ejector pins H13 46–50 HRC
Plunger shot sleeve H13 42–48 HRC
DIN 1.2367 42–48 HRC
Holder block 4140 prehard ~300 HB

 

Weight of aluminium castings can be from a few tens of grams to 32 kg. For aluminum alloys present restriction on the minimum thickness of the section of the article. These are 0,89mm (0.035’) and the minimum draft 0.6°