Hot Die Casting Process is a metal casting method for creating intricate parts using low melting point metals such as zinc and magnesium.
Hot die casting is a unique manufacturing procedure designed to create high-quality metal parts with precision and efficiency.
This procedure is especially beneficial for manufacturing intricate parts with small tolerances and polished surfaces.
It is especially favorable for metals like zinc, magnesium, and copper alloys which have lower melting points.
In this article, we will look at some of the most important steps in the hot die casting process and how it helps achieve quality metal parts.
The Hot Die Casting Process
The hot die casting process starts with preparing a certain metal alloy. The alloy needs to be at melting temperature in order to be injected into a hot cavity mold.
The mold is often made of steel or other sturdy materials that can handle the hot temperatures and high pressure of the process.
And then after the high temperature metal is injected into the mold cavity, it cools and solidifies rapidly which results in acquiring the desired shape. After the part is cooled, the mold is opened and the newly shaped part is removed.
- Preparation of the Die
- Material Preparation
- Injection of Molten Metal
- Solidification
- Ejection of the Casting
- Post-processing
Preparation of the Die
Die Preparation process begins with preparing the die, which consists of two parts crafted from high-quality steel. The die contains cavities that correspond to the shape of the final product.
And then to ensure uniform and quick solidification of the molten metal, the die is preheated to a specific temperature and held there.
Material Preparation
Material selection is equally important for hot die casting. Zinc, magnesium, and aluminum alloys are frequently used, each possessing distinct advantages for specific use cases.
For instance, zinc alloys are often utilized in precision small parts due to their exceptional surface finish. Magnesium alloys are lightweight yet strong, thus used for aerospace and automotive parts.
Aluminum alloys are used widely as they provide strength and durability along with corrosion resistance.
Injection of Molten Metal
The die is then filled with molten metal that is preheated to a specific temperature and held there.
The molten metal is then injected to the die under high pressure which ensures all details of the die cavity are filled, resulting in a part that is both precise and detailed.
Haichen’s advanced injection systems ensure precise control over the injection process, resulting in high-quality castings with minimal defects.
Solidification
After the metal is injected, it quickly solidifies inside the die. The solidification process is uniform and minimal defects like porosity or shrinkage are achieved due to high pressure and preheated die.
Ejection of the Casting
Once the metal solidifies, the die halves gets separated, and the casting is removed using an ejector pin. the casting undergoes additional processes such as trimming or finishing to remove excess material.
Post-processing
the casting is subjected to machining and heat treatment and other operations to improve the mechanical properties and cosmetic features.
Key Components of Hot Chamber Die Casting Machines
Hot chamber die casting machines consist of several key components, including:
- Furnace: Maintains the metal in a molten state.
- Gooseneck: Transfers molten metal to the injection chamber.
- Nozzle: Connects the injection chamber to the die.
- Plunger: Injects molten metal into the die.
- Hydraulic System: Powers the injection process.
Advantages of Hot Chamber Die Casting
Hot chamber die casting offers several advantages, including:
Less Material Waste: The continuous flow of molten metal reduces oxidation and material loss.
Haichen Hot Chamber Die Casting Machine Customer Case: Automotive Parts Smart Upgrade
Faster Cycle Times: Due to the integrated furnace, the process is quicker than cold chamber die casting.
Lower Energy Consumption: The continuous melting process reduces energy use.
Automated Operation: The process is highly automated, reducing labor costs and increasing consistency.
A russian automotive parts supplier adopted the Haichen HCD-H series hot chamber die casting machine for mass production of zinc alloy injector shells with stringent air-tightness requirements of 0.05MPa.
Core Challenges:
Slow production cycles and low yields of strongly overmolded thin-walled components which was sitting around 83%.
Haichen provided the customer with the following solutions:
The customer solutions provided by Haichen include ultra-high-speed injection (compression speed of 6m/s), intelligent mold clamping (2500T constant force), and advanced temperature control systems.
The customer’s product operation results:
The customer’s product operation results are as follows: yield increased to 98.5%, cycle time reduction to 19 seconds. And then mold life increased by over 40% surpassing 500,000 die times.
Hot die casting has a few advantages which includes high production speeds, great accuracy. And then the ability to produce thin walled intricate shapes.
In conclusion, these are used in the automotive, aerospace and consumer electronics industries. Or, it is used to make parts like engine housings and electronic casings.
