Aluminium Die Casting
Casting of metals under pressure is a method of manufacturing castings from alloys, in which the alloy acquires the shape of a casting, quickly filling the mold under high pressure. This method is used for alloys of non-ferrous metals (based on zinc, aluminum, copper, magnesium, tin-lead alloy) because of their low melting point, and for some steels. The resulting products can be from tens of grams to tens of kilograms. we called this process as high pressure die casting process
The main advantages of aluminium die casting under pressure are high productivity, minimal need for machining the product, and the fact that the blanks obtained in this way have a high surface quality.
Die-casting of aluminum under pressure is widely used for medium-series, large-scale or mass production of castings. The method of casting aluminum under pressure is widely used in the field of automobile and aircraft building, electrical engineering, instrument making, etc.
The main advantages of the pressure die casting method
- Productivity and economy.
The classical casting of aluminum alloys under pressure is still the most productive and the most economical. Therefore, aluminum in the form of castings under pressure still has the largest share among processed metals.
- Aluminum remains promising.
Industry, especially automotive, requires more and more light parts. Due to this and the above reasons, aluminum remains an indispensable material. The raw materials, bauxites, are available in large quantities. This gives us confidence that we will be able to innovate for a long time and work with aluminum for the future.
- Aluminum is relatively easy to melt.
- Metal is recycled – an important advantage in terms of environmental protection.
Another known casting method is zinc die casting. Technically pure zinc has satisfactory mechanical 
properties, it is well suited for rolling,
pressing, drawing and stamping in the cold state and in the temperature range 130 -170 degree. Zinc has a high density in the solid and liquid state, low melting and boiling temperature, linear shrinkage. They produce several brands of zinc, which differ in the quantity of impurities.
The main applications of zinc die-casting under pressure are the production of door fittings, carburetor cases, pumps, decorative elements, as well as the font-making industry. The parts made of zinc have a high density and well repeat the relief of the mold, therefore it is possible to make castings from them with already printed pattern and very small details.
Magnesium Die casting under pressure. The guaranteed availability and the combination of the positive properties of high purity magnesium alloys make the lightest metal structural material attractive for use in many industries, for example:
- Lightweight parts for the automotive industry.
- Cases for office machines, laptops, mobile phones and speakers.
- Machines for domestic work, etc.
Properties and advantages of the method.
- Due to very good fluidity, it is possible to produce even finer-walled or more complex parts than with aluminum die casting.
- New applications in the electrical industry due to good thermal conductivity, as well as electromagnetic shielding of the metal.
- Compared with plastics, greater strength and better thermal conductivity are achieved.
- Magnesium reserves are practically inexhaustible.
- Negotiable material is processed secondarily.
- High-purity magnesium alloys are less susceptible to corrosion.
- Good sound insulation properties from noise.
- Weight reduction of approximately 30% compared to aluminum.
Die casting is one of the most advanced methods of mass production of castings.
Along with such advantages, injection molding has a number of disadvantages.
1) High cost of basic equipment and molds;
2) Formation of porosity and shells in massive sections of castings, in connection with which the strength and tightness are reduced, thermal treatment of castings, is excluded;
3) It is possible to fill only aluminum, magnesium, zinc and copper alloys ( brass die casting ), but not all fusible alloys, even aluminum, can be used for injection molding.
The economic feasibility of casting in one way or another, except for the technological design of the construction of the part, is determined by the laboriousness of manufacture and the technological possibility of making castings. The high cost of tooling equipment leads to the fact that the manufacture of castings by injection molding is economically feasible when ordering more than 20,000 pieces. With smaller orders advisable other methods.
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