What is Hot Chamber Die Casting?

One manufacturing technique that revolutionized the industrial world is die casting. Though this technique may sound very simple, it has been effective in reducing production expenses and increasing production count. Die casting is a process in which metal is melted in to its liquid form and then poured into the cast. The design of the cast is created based on the final product design. After the metal is poured into the cast, it is allowed to cool. The liquid metal solidifies into the particular shape. This concept is the basis for zinc alloy die casting and magnesium die casting

There are two types of die casting used in the manufacturing world. One is hot chamber die casting and the other is cold chamber die casting. If you look at the set up for the hot chamber zinc alloy die casting, you will see the following components. It will have a gas/oil accumulator, piston, mold, casting cavity, gooseneck passage, hot chamber and toggle clamp.

First, the molten metal is filled in the cylinder. Next, a plunger forces the liquid metal in the cylinder into the die cavity through the goose neck passage. This passage allows the fluid metal to slowly start cooling. The shape, size and length of this passage will have a direct influence on the outcome of the magnesium die casting. The molten metal in the passage then flows into the cavity. A nozzle is placed at the end of the passage, so a consistent level of pressure is maintained when the liquid metal is poured into the cavity. This pressure is important for the fluid metal to completely spread inside the cavity of the cast. It also allows for uniform distribution of the molten metal. Once the mold is filled, the plunger is brought back to its original position. So, any remaining molten metal flows back into the cylinder. This prevents overfilling of the cast, which could damage the design and the final product.

This metal is allowed to cool, and the cast is broken to remove the finished product. The cooling time depends on whether you are working on zinc alloy die casting or magnesium die casting. The melting points and other properties of the metals are different, and the cast design and process will be modified to suit each type of metal. Careful planning and design will give you consistent results in hot chamber die casting process.

The Benefits of Zinc Alloy Die Casting

Die casting is a manufacturing process that involves forcing high pressure molten metal through a mold and then instantly cooling it. This method is very useful for creating many machine parts and accessories. A number of metals and metal alloys are used in the die casting process. Each material has its own set of advantages, disadvantages and applications. The manufacturer identifies the right type of material to use based on the properties expected from the end product.

Of all the metals used for die casting, zinc alloy is the most preferred for its economical properties. This metal alloy is easy to cast and also offers durable use. Moreover, this material is highly ductable and can be easily plated on any surface. Zinc alloy die casting is very sturdy and has a high impact strength.

It is generally used in the cold chamber die casting technique. In this technique, zinc alloy is melted in a separate furnace and then poured into a cold chamber from where it is moved into casting. As it has a low melting point,zinc alloy can also be used in hot chamber method, if required. This versatility makes it the best choice for most manufacturing processes. As this material has a low casting temperature, its thermal shock is less, which results in longer tool life. Another advantage of this low casting temperature is that it reduces energy use, and makes it more ecofriendly.

Another benefit of zinc alloy die casting is that it can be made into casts with very thin walls. Plus, the cast surface is very smooth, and can be easily plated or painted upon. These alloys have a matt anti-sparkling finish, which makes them a good choice for use in refineries, tankers and coal mines. The machining characters of zinc reduce normal wear and tear. So, parts cast with this alloy can be used longer and deliver better performance.

Most manufacturers prefer to use zinc alloy die casting technique as the material has high dimensional stability, hardness as well as good thermal and electrical conductivity. Plus, its self-lubricating properties make it a good option for manufacturing pinons and gears. Its excellent bearing properties make it suitable for industrial applications.

The best part of using zinc alloy in various manufacturing processes is that it is clean and recyclable. The alloys are zinc are not toxic or harmful to the environment. So, the scraps can be recycled and used again.

Why Zinc Alloy Precision Die Casting is Suitable for Manufacturing Small Gears?

Die casting is a manufacturing process in which molten metal is poured into a cast and then cooled till it achieves the right shape. Die casting has brought about a huge change in the entire manufacturing cycle by speeding up the process and enhancing product quality. Zinc alloy die casting gives manufacturers great potential for manufacturing products in large volumes at reduced prices. Moreover with precision castings even complex shapes and designs can be created with apparent ease. The castings are also very sturdy, which enhances their performance and durability.

As with most manufacturing processes, precision die casting also greatly reduces production costs and time in the manufacturing of small gears. Using zinc alloy die casting, one can manufacture spur, helical or worm gears, all using a single type of casting. From simple to complex sizes and shapes, die casting can be used to produce almost any type of gear. It may sound impossible, but die casting makes it possible as it has the ability to bring together the unique components of all gears into one cast.

When the tool design is created, four side cores can be put together to create the worm gear cavity. The molten metal is poured into the bore at the centre, which then evenly spreads across all the tooth casts and slowly sets into the right shape. As zinc alloy has great strength even when it is made into thin walls, you can be assured of the sturdiness and durability of the finished product. The exact amount of metal required to produce the gear is used, so you will be able to reduce a lot of metal waste.

Another reason why zinc alloy die casting is an affordable option for manufacturing of small gears is that it reduces the need for the secondary finishing options. Precision castings decrease the need for secondary tasks that are generally carried out after the product is manufactured. To illustrate:

Indicator, timing marks, date, part number or other details can be carved or embossed in the casting. So when the metal is cast, the details are automatically embedded into the gear. You don’t need a separate process to mark all these details.

Also, if you need a parting line in the gear, while die casting zinc, simply mark the exact position in the mould. The parting line will accurately appear in all the gears.

There are lots of other ways in which zinc alloy die casting proves to be beneficial in the manufacture of small gears, which is why it is used in precision castings of gears.

Emerging Trend of Zinc Alloy Die Casting

The dusk of Stone age gave rise to the new beginning of metal age which was differentiated between Bronze age, Iron age and Copper age. Formation of cities, migration of people and commerce had begun during this era. Metal manufacturing work was in its crude stage. Banking on a variety of useful factors and metal properties people used metals extensively even in the past as this made their life much simpler. They used metals for making utensils and weapons due to its property of malleability and ductility. And most of all, it is the strongest material. As days passed this restricted use of metals expanded its dimensions and became the most essential aspect in our everyday life.

In today’s modern world, even the construction works use metal as their base and the machines working on spare parts are designed out of metals. Recognizing the ever growing demand the advancement of technologies took a stand. Metal manufacturing process gained a refined process and the crude metal work has now turned into fine and polished finish as we are now deploying the method of metal die casting. Today, the use of die casting has been in extensive use to meet the ever increasing orders as this process can make numerous metal units with uniform structure and design.

Technique of die casting is a process in which metal spare parts are made by putting liquefied metal into molds or dies. With this technique one can easily produce a complicated design with high accuracy. The die casting method produces parts with fine surface which reduces costs of remaking or refining the same part. Out of a variety of metal casts like aluminium cast alloy or magnesium cast alloy, the zinc alloy die casting is extensively used due to its higher tolerance level. Zinc alloy has a capability of producing very thin wall casting which ultimately produces much lighter component with the employment of lower cost.

Zinc casting is widely used for mass production, not only in the automotive industry but also in electronic equipment’s. Along with this, it is also used in various decorative materials as it can be easily polished or painted or can be given a matt finish to make it more attractive. As zinc has good conductivity of heat as well as electricity and high tolerance, it is used in electromagnetic screening. Zinc has a property of self-lubricating and is a hard alloy which is considered as durable properties; hence zinc alloy die casting is used in making of automobile parts and the gears of any machine. Its non-sparking attribute adds its application in the mining industry as well as in refineries. The strongest property of zinc alloy is its nontoxic nature that makes it a reusable and recyclable material.

The Benefits of Zinc Alloy Die Casting

Die casting is a manufacturing process that involves forcing high pressure molten metal through a mold and then instantly cooling it. This method is very useful for creating many machine parts and accessories. A number of metals and metal alloys are used in the die casting process. Each material has its own set of advantages, disadvantages and applications. The manufacturer identifies the right type of material to use based on the properties expected from the end product.

Of all the metals used for die casting, zinc alloy is the most preferred for its economical properties. This metal alloy is easy to cast and also offers durable use. Moreover, this material is highly ductable and can be easily plated on any surface. Zinc alloy die casting is very sturdy and has a high impact strength.

It is generally used in the cold chamber die casting technique. In this technique, zinc alloy is melted in a separate furnace and then poured into a cold chamber from where it is moved into casting. As it has a low melting point, zinc alloy can also be used in hot chamber method, if required. This versatility makes it the best choice for most manufacturing processes. As this material has a low casting temperature, its thermal shock is less, which results in longer tool life. Another advantage of this low casting temperature is that it reduces energy use, and makes it more ecofriendly.

Another benefit of zinc alloy die casting is that it can be made into casts with very thin walls. Plus, the cast surface is very smooth, and can be easily plated or painted upon. These alloys have a matt anti-sparkling finish, which makes them a good choice for use in refineries, tankers and coal mines. The machining characters of zinc reduce normal wear and tear. So, parts cast with this alloy can be used longer and deliver better performance.

Most manufacturers prefer to use zinc alloy die casting technique as the material has high dimensional stability, hardness as well as good thermal and electrical conductivity. Plus, its self-lubricating properties make it a good option for manufacturing pinons and gears. Its excellent bearing properties make it suitable for industrial applications.

The best part of using zinc alloy in various manufacturing processes is that it is clean and recyclable. The alloys are zinc are not toxic or harmful to the environment. So, the scraps can be recycled and used again. 

Advantages of Zinc Alloy Die Casting

Die casting is a very common metal casting process that involves forcing molten metal into a mold cavity under high pressure conditions. Two hardened tool steel die casts are used to create the mold cavity. These are machined into the shape required, and work just like an injection mold. Usually, non-ferrous materials like copper, zinc, magnesium, aluminum, lead, pewter, and tin based alloys are used for creating the die casting. Either hot or cold chamber machine is used, depending on the type of material that is being cast. Zinc die casting is a popular die casting process that employs zinc metal.

Die casting is very commonly used because of the advantages of the process:

     ·         Exceptional dimensional accuracy can be obtained, which is typically  mm for the first  cm and  mm for every additional centimeter

     ·         Really smooth cast surfaces can be obtained

     ·         It is possible to cast really thinner walls as compared to the sand and permanent mold casting

     ·         Secondary machining operations are not required

     ·         Production rates are really high

     ·         Inserts like heating elements, threaded inserts and high strength bearing surfaces can be cast in

     ·         High tensile strengths of about  mega Pascals can be achieved for the casts

     ·         Low fluidity metals can be cast

The only disadvantage of the die casting technique is the high capital cost involved. But, the advantages outweigh this one disadvantage of the process. Among the different die casting processes, zinc alloy die casting is one of the most common.

Zinc is a very common metal that is easily available and used. The main reason for opting for zinc die casting is that these castings are safe, secure, convenient, and also act as a decoration. Their physical characteristics and mechanical properties make it a perfect option for all requirements.

Zinc alloy die casting is well known for the hardness and strength. It is an ideal metal that can be used in place of other stamped, pressed, machined, and fabricated items. Zinc alloys are known to have the following characteristics that make it an ideal metal for the die casting process:

     ·         Very hard

     ·         High strength

     ·         High thermal conductivity

     ·         High stability

     ·         Dimensional accuracy is high

     ·         The raw material is of low cost and affordable

     ·         Joining is eased by the ability to cold form

     ·         Thin wall capability is high

     ·         Finishing characteristics are of high quality

     ·         Resistance to corrosion is just outstanding

     ·         Full recyclability can be achieved

So, now that you see why most companies prefer to use zinc and zinc alloys for die casting and other manufacturing purposes, you can even start using the process for your machinery and equipments.

Uniformity Dwells in Die Casting Design

Any tool manufacturing company, be it an automobile, gadget or toy making companies are involved in mass production for which uniformity is of prime importance. With respect to size, shape, structure, calibration, etc., one can hardly find any difference. The basic concept behind this uniformity is a die that is used for manufacturing. Every product is designed with high accuracy and with finished surface with the help of die casting. The use of die casting is cost effective as it nearly eliminates the need of refinishing or scraping any part. The assembly line is reduced, resulting in cost efficiency and reduction in assembly time. All this can be made possible with the use of suitable die casting design.

Let us basically focus on the concept of die casting. The furnace is used for die casting in which the metal is melted. And this molten metal is forced under pressure into a cavity of mold. This mold is made with the use of two steel dies which are hardened. These molds are shaped into the required die casting design. These dies are designed in such a way that it can produce any required shape, be it complex or the simplest. But the outcome is accurate and uniform. Though the process to make parts with the use of die casting is simple the metal dies and casting machines involve huge capital cost. Thus, there is a need of mass production.

Non-ferrous metals or alloys of metals like zinc, aluminum, copper, magnesium, tin or lead are used to make the die casting. The process of die casting involves two types of machines viz. hot chamber machine and cold chamber machine. Hot chamber machines are used for alloys having a low melting point like zinc, lead and tin, whereas cold chamber machines are used for alloys like aluminum, copper and magnesium that has a high melting point. Once the molten metal gets injected into these molds, it cools down and attains solid state on these machines which is known as the casting. The process of direct injection is used for making zinc alloy die casting so as to get fine surface and better finishing. The plating zinc alloy is essential as it can undergo corrosion when exposed to salt water. Hence, it has to be coated in order to maintain its luster.  

Instead of brass or iron cast, zinc alloys are always preferred, though its tensile strength is lower. Its melting point is around 800 degree Fahrenheit.  Zinc alloy die casting is highly beneficial as it has a low melting point and die casting using zinc alloy is easy to fabricate as it is highly ductile. It can be coated with ease and the final outcome is flawless and can retain its luster for longer period.