In die casting, the mould (called a die) must withstand high temperatures, pressure, and repeated cycles. The Die casting Mould material used are high-performance metals designed for durability, thermal stability, and wear resistance.

The die-casting mold consists of two parts, separated according to the product’s draft angle. Molten metal is poured in from the fixed end, and the die-casting part solidifies upon cooling. The die-casting part remains on the movable side, which is ejected by ejector pins. After removing the die-casting part, we recommend applying lubricant to the mold using a spraying machine.

Designing and manufacturing die-casting molds requires expertise and skills in mold making, metallurgy, and engineering. The quality of the mold significantly impacts the quality, consistency, efficiency, and overall production cost of the die-casting process. Therefore, selecting the appropriate mold material is crucial for the success of the die-casting process.

Primary Die casting Mould material

• Tool Steels 
• Maraging Steel
• Copper Alloys 
• Hot Work Steels

• Tool Steels (Most Common)
  • H13 (AISI/SAE):
    • Composition: Chromium, molybdenum, vanadium.
    • Properties: Excellent thermal fatigue resistance, high hardness, and good thermal conductivity.
    • Applications: Aluminium, magnesium, and zinc alloy die casting.
    • Lifespan: ~100,000 to 1,000,000 cycles, depending on cooling and maintenance.
  • H11 (AISI/SAE):
    • Similar to H13 but with slightly lower toughness. Used for smaller or less complex dies.
  • DIN 1.2344 (European Standard):
    • Equivalent to H13, widely used in Europe.
• Maraging Steel
  • Composition: Nickel, cobalt, molybdenum.
  • Properties: Ultra-high strength, excellent dimensional stability, and resistance to cracking.
  • Applications: High-pressure dies for complex parts (e.g., automotive components).
• Copper Alloys (for Inserts)
  • Composition: Copper with beryllium, chromium, or tungsten.
  • Properties: Superior thermal conductivity for rapid cooling.
  • Applications: Inserts in critical areas (e.g., around cores or thin walls) to reduce cycle time.
• Hot Work Steels (e.g., DIN 1.2714):
  • Used for high-stress components like ejector pins or cores.

Key Requirements for Die casting Mould material

• Thermal Fatigue Resistance: To handle repeated heating/cooling cycles (critical for aluminium/magnesium casting at 600–700°C).
• Wear Resistance: To endure abrasive molten metal flow.
• High Hardness: Maintains shape under high clamping pressures (up to 2,000+ bar).
• Machinability: Allows precise die cavity shaping.

Surface Treatments

To enhance performance:

• Nitriding: Creates a hard, wear-resistant surface layer.
• Coatings (e.g., TiN, CrN): Improve corrosion resistance and reduce soldering (metal sticking to the die).

Die casting Mould material Selection Factors

• Cast Metal
• Production Volume
• Part Complexity

• Cast Metal:
  • Aluminium/Magnesium: Require H13 or maraging steel (high melting points, ~600–700°C).
  • Zinc: Softer alloys allow use of lower-cost steels (e.g., P20).
• Production Volume:
  • High-volume runs (millions of cycles) demand premium steels (H13 with coatings).
• Part Complexity:
  • Complex geometries need tougher steels to prevent cracking.

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Typical Die Lifespan

Cast Metal	Die Material	Lifespan (Cycles)
Zinc	H11/P20	1,000,000+
Aluminium	H13 (Nitrided)	150,000–500,000
Magnesium	H13/Maraging	100,000–300,000

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Applications

• Automotive: Engine blocks, transmission housings (H13 steel).
• Consumer Electronics: Smartphone frames (zinc dies with P20 steel).
• Aerospace: Lightweight magnesium components (maraging steel).

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Advantages of Die Casting Moulds

• Reusable for high-volume production.
• Deliver tight tolerances (±0.1 mm) and smooth surfaces.
• Minimize post-processing compared to sand or investment casting.

Haichen die casting mould

Haichen Die Casting Mold Design and Applications: Key Features
Based on comprehensive analysis of multiple sources, Haichen’s die casting mold technology exhibits the following characteristics:

• Flexible Mold Configurations
• Standardization & Precision Engineering
• Material Compatibility
• End-to-End Solutions
• Mold Maintenance & Lifespan
• Real-World Applications
• Certifications & Quality Control
• Mold Size Range

Flexible Mold Configurations

• Haichen’s cold chamber die casting machines support single or dual cavity molds, enabling users to adapt to production needs (e.g., radiators, automotive parts). This flexibility suits scenarios requiring high-volume production or diverse product types.

Standardization & Precision Engineering

• Mold designs comply with Chinese mechanical industry standards (JB/T series) and EU CE safety regulations, ensuring structural integrity. Critical components are optimized via Finite Element Analysis (FEA) to enhance durability and dimensional accuracy.
• The cold chamber machines use magnetic encoder-controlled injection positioning, with PLC-managed four-stage injection (slow, first fast, second fast, intensification), minimizing molten metal turbulence and reducing mold wear.

Material Compatibility

• Cold chamber machines handle aluminum, magnesium, and copper alloys (high melting points), requiring molds with heat-resistant designs. Example: Aluminum radiator molds enable single-piece casting for improved thermal efficiency.
• Hot chamber machines specialize in zinc and lead alloys (low melting points), featuring integrated mold-furnace designs (e.g., gooseneck structures) to shorten metal flow paths and enhance fill efficiency.

End-to-End Solutions

• Haichen offers full-process services, from mold design to machine configuration, including Mold Flow Analysis and process optimization. Example: Precision zinc alloy lock cores and door handles achieve lightweight yet robust designs.
• Multilingual control systems (Chinese, English, Russian, etc.) simplify global operation and parameter adjustments.

Mold Maintenance & Lifespan

• Hydraulic systems integrate European/American components (e.g., Vickers, Rexroth) for stability, reducing mold damage from pressure fluctuations.
• Smart lubrication systems: Centralized lubrication every 500–700 cycles; manual lubrication points serviced biweekly (first 6 months) and monthly thereafter.

Real-World Applications

• Aluminum cookware molds: Achieve uniform thick-walled casting for heat resistance.
• LED housing molds: Optimized for heat dissipation with automated part removal.
• Zinc alloy medal molds: Support intricate polishing/plating processes (final thickness: 1.3–1.4 mm).

Certifications & Quality Control

• Molds meet ISO 9001 and CE certifications, complying with GB/T 21269-2023 standards. Critical tolerances: Dynamic platen parallelism ≤0.12 mm.

Mold Size Range

• Cold chamber machines accommodate mold thicknesses from 200–580 mm (200-ton models) to 400–950 mm (880-ton models), catering to diverse product dimensions.

Summary: Haichen’s die casting molds excel in precision engineering, material adaptability, and intelligent maintenance, synergizing with high-ejection-control machines and stable hydraulics. These capabilities serve automotive, appliance, and hardware industries with robust, high-quality production outcomes.

Die materials are a critical investment, balancing upfront cost with long-term durability and part quality.