What is High-Pressure Casting (HPDC)?
Die casting is the process of producing metal parts by forcing molten metal into a machined mold cavity under high pressure. The die casting method is ideal for applications that require a large amount of small and medium-sized parts. It requires details, surface quality, and shape stability. Almost all molded parts are made of non-ferrous metals, especially zinc and aluminium. The variety of die-casting has made it one of the most mass-produced processes in the metallurgy industry.
How does the high-pressure casting process work?
The high-pressure horizontal casting machine makes sure the mold is completely closed. This is classified according to the amount of clamping force that can be applied. For Italpresse Gauss machines it goes from 550 tons to 5700 tons.
Depending on the metal used, the injection unit filling the mold can be a hot chamber or a cold chamber. In hot chamber die casting, the metal is held in a die casting machine. Then the metal is brought into the chamber and the mold by the deed of the inoculation piston. These divisions of the apparatus are always getting in touch with the molten metal.
In the cold room process, the metal is first melted in another furnace and transferred to a holding furnace. Then it is poured into the filling chamber and injected into the mold. Italpresse Gauss offers a wide range of high-pressure cold chamber casters.
Advantages of the high-pressure casting process
High-pressure casting technology can produce very large Die Cast Aluminum Alloys part at high volume and high speed.
The high-pressure casting process can also produce thin-walled components and castings, as well as various types of parts such as screws and linings.
Application
Cold chamber high pressure die casting technology is ideal for manufacturing a wide range of automotive aluminium and magnesium components.
They were widely used in other industries to manufacture application components ranging from the simplest (lighting components) to the most demanding (aerospace engine components).
Advantages of die casting:
1. Good product quality
The dimensional accuracy of casting is high, generally equivalent to 6-7, up to 4.
Good surface finish, generally equivalent to 5-8.
It has high strength and hardness, generally 25 to 30% higher than sand mold casting, but the dispersion rate is reduced by about 70%.
The size is stable, and the compatibility is good.
It can press-mould thin and complex molded products. For example, current zinc alloy castings have a minimum wall thickness of 0.3 mm.
2. High production efficiency
The die casting type has a long life and is a die casting type. Alloy die castings with a life of hundreds of thousands or millions. Easy to machine and automate.
3. Excellent economic results
Due to the exact size of the die casting parts, the surface is shiny and clean. Generally, they are not mechanically processed and used directly, or the amount of processing is small. It improves the metal utilization rate and reduces a large number of processing equipment and working time. The casting price is simple. Composite Aluminum Die Casting can be used for other metallic or non-metallic materials.
While die casting has many advantages, it also has some drawbacks that have not yet been addressed.