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Die Casting Process


Below will explain how Aluminum Die-Casting process is performed to help understand the theory of Die-Casting.





Before the Die-casting process can begin, the initial step is to upload the die halves on to the Die-Casting machine.


Machine size for the casting depends on the weight and Die-Casting surface area of the casting. This process involves changing suitable plunger and plunger sleeves for the shot parameter and changing ladle for the right weight. After the Die is set up, we heat up the Die with soft flame by gas torch.


When the Die is well heated up, we apply solidus lubricant around the gating area and deep/thin features to protect the Die from high pressure/temperature during shots.





In this phase, the aluminum ingots were loaded and melted by central melting furnace, and it remains in a molten state at 720 degrees.


Then the molten aluminum is transferred by our transfer bowl from the melting furnace to the holding furnace by the machine side using forklift operated by human.


The reason for human operation is mainly safety concerns.


The Die-Casting machine ladle then scoops the aluminum from holding furnace and pour into the plunger sleeve and the hydraulic system then injects the molten aluminum into the Die cavity.


This process takes only 0.1 sec for the aluminum to turn from liquid to solidus state.





The aluminum starts to cool down in the cavity for 5~15 secs depend on the nature of the castings.


It is crucial for the casting to cool and solidify in the Die with good timing.


Premature opening of the Die can lead to casting explosion and delayed opening of the Die can lead to deformations.


Aluminum Die-Castings often consist of various wall thickness which makes the cooling time even more crucial to quality.


So, it is vital to keep all these factors in mind.





The Die-Casted parts are then ejected out of the Die by the ejecting mechanism.


The extracting machine then clamps the gating section and removes the casting from machine to the conveyor line for slow cooling.


Gating and overflows will be removed by operator and gauge and visual inspection will be performed.







Mold designing, dimension inspection, and mold surface spotting

Mold design is a crucial part of the development process for molding success.

Therefore, we craft mold designs to meet both design specifications & customer expectations.

We decide the location of the sprue gates, flow aids, etc., and select the suitable mold design.




Liquidating and holding molten aluminum process

Aluminum is melted at 590 degrees temperatures, but it must be melted to 720 degrees for all chemical composition to be integrated.

Every Die-Cast machine has its holding furnace, which keeps the molten aluminum in a liquid state at working temperature before the injection phase begins.




Die-casting process

In this step, the molten aluminum is injected the die halves, and holds in the Die to maintain structural integrity.





Ejecting the solidified casting from the tooling comes next.

The ejecting mechanism evenly push out the casting from the tooling and the extractor clamps it and transfer it to the conveyor.





After the casting is extracted, operator will inspect for any defects (deform, flow mark, soldering, drag mark, broken pin, shrink mark, crack, porosity etc...) and adjust parameter if needed.