ODM Supported High Pressure Deburring Aluminum Stamping Parts

Product Specification

Deburring Iso2768-Mk Aluminum Stamping Parts
 

Product Description and Process

ADC12 High Pressure Aluminium Die Casting Parts Custom Casting Manufacturer

Production process: aluminum die casting process

Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.

Surface treatment process: anodic oxidation, Dacromet coating, etc.

Product Material and Uses

Normally produce with JIS ADC1, ADC3, ADC5, ADC6, ADC10, ADC12, ASTM A413, A360, A380, A383, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.
 

Die casting

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.

Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process.Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.

Two variants are pore-free die casting, which is used to eliminate gas porosity defects; and direct injection die casting, which is used with zinc castings to reduce scrap and increase yield.

Hot-chamber die casting

Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The pneumatic- or hydraulic-powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that it is limited to use with low-melting point metals and that aluminium cannot be used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber machines are primarily used with zinc-, tin-, and lead-based alloys.

Cold-chamber die casting

These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace. Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. The biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine.

Advantages of Metal Die Casting Process

1. Aluminum (aluminum alloy) die casting has advantages of lightweight, excellent corrosion resistance, good mechanical properties, high thermal and electrical conductivity, high dimensional stability for complex shapes and thin walls, and retains strength at high temperature.

2. Zinc die casting is the easiest alloy to cast and plate, which features high ductility, high impact strength, promoting long die life as well as economical for small parts.

3. Magnesium die casting is the lightest and easiest alloy to manufacture with excellent strength-to-weight ratio.

4. Copper (brass, bronze) die casting features high hardness, good corrosion resistance, highest mechanical properties of alloys die cast, good wear resistance, excellent dimensional stability and high strength that approaching steel parts.

5. Stainless steel die casting has high degree of dimensional accuracy and surface finish, with a small amount of mechanical processing work, which greatly saves a large equipment, metal material and working hours.

6. Lead and tin die casting high density, extremely close dimensional accuracy, used for special forms of corrosion resistance.

Capabilities

1. Ability to manufacturing complex cast molds and metal parts.

2. The precision machining after casting.

3. Strict quality control and testing report, includes: X-Ray, Chemical Composition, Mechanical Property Test, CMM dimensional checking.
 

The Best Aluminum Alloys for Die Casting

It is generally agreed that die casting with aluminum is one of the most cost-effective and sustainable ways to create metal parts. When using aluminum, you will have to choose which aluminum casting alloys to use in the process. Here is some technical information on aluminum alloys to help you get a better sense of your alloy options and why we choose the alloys we prefer.

A380 Aluminum Alloy

The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures and corrosion resistant. A380 is also very good at retaining dimensional stability even with complex shapes and thin walls and offers high electrical and thermal conductivity.

A383 Aluminum Alloy

Another option for die casters is to use A383 aluminum alloy. This is alloy is typically only used when you are forming intricate components and require very specific die-filling characteristics. While it doesn’t share all the properties of A380, it does offer higher strength at high temperatures with less chance of cracking under heat.

A360 Aluminum Alloy

A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.

A360 vs. A380 v. A383

To summarize the differences between the three types of casting alloys as outlined above, A360 has the best pressure tightness, high-temperature strength and corrosion resistance of the three alloys.

A380 is also highly corrosion-resistant but more cost-effective and easier to work with than A360, so this is the one you would use most commonly if you have budgetary concerns to consider and don’t need the highest levels of corrosion resistance or pressure tightness.

A383 is a modified A380 alloy you would only use if you need precise die filling that you are not getting from your A380 alloy, as it is not as durable as A380.

ZA Alloys

Some applications may call for ZA, or zinc aluminum alloys, for your die casting. Originally the primary type of alloy used in gravity casting, scientists have refined this type of alloy for effective use in die casting. The three alloys that fall into this category are ZA-8, ZA-12 and ZA-27. Alloys that combine zinc and aluminum offer higher strength, lower density, better creep resistance and better wear resistance than other zinc alloys.

ZA-8

ZA-8 is the only hot chamber alloy of the three. It is the zinc aluminum alloy one uses in die casting with the lowest possible aluminum content. It features an aluminum content of 8.4 percent with one percent copper. Because of the minimal aluminum content, ZA-8 has a lower melting point and higher density than other zinc aluminum alloys. This makes it ideal for hot-chamber die casting. It’s often used for higher strength requirements that need plating.

ZA-12

ZA-12 has somewhat greater aluminum content than ZA-8 but less than ZA-27, so it offers a sometimes desirable mediation of zinc alloy properties. It has 11 percent aluminum and one percent copper content. It provides the best combination of castability and strength of the ZA alloys. Because of its higher melting point and lower density, if you are using ZA-12 for casting, you must use the cold-chamber method.

ZA-27

ZA-27 is the strongest of the three ZA alloys, but difficult to cast. It has the highest aluminum content of all the zinc-aluminum alloys we use for die casting, with an aluminum content of 27 percent and copper content of 2.2 percent. The result is a material with the highest melting point, highest strength and lowest density.

Unlike other zinc aluminum alloy parts, parts made with ZA-27 are typically not ideal for chrome plating. As with ZA-12, you cannot use this alloy with hot-chamber casting because of its high melting point. Underside shrinkage can be an issue in die casting for ZA-27 – so cooling rates need to be looked at carefully.

We are a professional supplier of die casting in China, offering a high quality affordable, metal die casting process solution. We also provide the following services:

1. Heat Treatment: Hardening, Annealing, Normalizing, Stress Relieving, Softening, and Graphitization.

2. Machining: Turning, Boring, Drilling, Milling, Threading, Grinding, Cutting, Engraving, EDM Machining, Riveting.

3. Surface Treatment: Metal Polishing (Metal Mirror Polished, Brushed Metal Finishing), Shot Blasting, Sandblasting, Spray Painting, Powder Coating, Thermal Spraying, Anodizing, Chrome Plating, Nickel Electroplating / Electroless Nickel Plating, Hot-Dip Galvanizing, Copper Plating, Phosphorizing, Electrophoresis and Passivation.

4. Assembly: Stud, Steel Sall & Helicoil Inserts, O-ring, Gasket

5. Packing

6. Testing Report, Quality Control Report