DIE CASTING ALUMINUM CASTING
Precision is a manufacturer specializes in aluminum casting , aluminum die casting, magnesium die casting and zinc die casting processes. Company is also specialized in the design, development, manufacture the aluminum die casting mold, magnesium die casting molds and zinc die casting mold with our complete manufacturing facilities and professional technologies. The great communication with international customers are our strength to insure the qualify molds and raw casting components. With the precision raw casting component, it raises the dimensional accuracy and saves the cost from the post CNC machining and relative manufacturing processes.
We hope to make a useful resource for custom engineered components and materials. With broad background in casting, post manufacturing, painting and plating processes, we provide the technical information and news pertaining to cast, wrought material and machined methods. Our good English speaking engineer is willing to assist you to make the proper design in your best interest. We have no agenda other than helping our customers improve their product and reduce their manufacturing cost.
We encourage you to contact and consult with us in your product development stage for an appointment and a detail analysis of your part. We can provide recommendations on design, material and appropriate process to ensure your product is designed with optimal condition for manufacturing. We can also estimate pricing and lead-times result in smooth production and fast delivery with reasonable accuracy.
We invite you to evaluate the information provided in this website. We are positive it will provide many answers with regard to the general design of metal die casting and plastic injection.
If your requirement and interest goes beyond this grade, you are very welcome to phone, fax or email our facility. We would be happy to tell you our recommendations of your questions and designs at no obligation.
Here, we would like to guide you to choose the proper selection of casting methods.
Die Casting : The molten aluminum, magnesium or zinc alloy is injected by die casting machine into the hardened steel die with suitable pressure. Normally the mold and castings are cooled down by water. When the raw castings turn solid the dies (female and male dies) will open and ejector the castings. The cost of die casting die is very high to compare with the other casting mold. In the same component, the die costs between aluminum alloy and magnesium alloy are very close, due to they use the same steel for making mold. Using the same steel, because their casting temperatures are the same high (all more than 670°C). The casting temperature of zinc die casting is lower, it is around 450°C. The choosing mold steel doesn’t need to be same high end with aluminum casting and magnesium casting. The mold cost is lower for sure. The die casting machines generally could be separated by 2 styles, hot chamber and cold chamber. The casting cycle time is shorter for hot chamber machine, so it is selected to cast the smaller part with complicate shapes. The cold chamber machine normally is selected to cast the big size parts. We can execute both hot and cold chamber machines to ensure the custom components can be casted with suitable die casting machine.
Magnesium die casting molds are with oil tubes in both male and female molds, the tubes need to be connected with the supply pipes of oil mold heater to rise the mold temperatures. The mold heater supply the high heat oil (more than 250°C) through the pipes into the steel die to heat it. The Magnesium dies need higher mold temperature due to magnesium alloy turn cold and solid very fast in mold. The high heat mold temperature increases the mold flow and slow down the cooling of molten metal. On the contrary, Aluminum die casting doesn’t need to use mold heater during the casting processes. It certainly increases the casting cost of magnesium die casting.
The size rage of component: It is smaller than 2 feet square normally. Our foundry is capable of larger size for some designs.
General tolerance of component: Al and Mg: +/-0.002”/in., Zinc: +/-0.0015”/in.
Minimum draft angle requirements: Al and Mg: 1° to 3°, Zinc: 1/2° to 2°
Minimum section thickness: Al: 0.03” for small parts, 0.06” for medium parts
Mg: 0.03” for small parts, 0.45” for medium parts
Zinc: 0.025” for small parts, 0.040” for medium parts
Minimum ordering quantities: 1,000 pcs and up usually. It depends on the component sizes and shapes. The bigger size components allow smaller MOQ, however the casting cost per piece will be higher due to the big tonnage machine usage and the longer casting cycle time. Castyield Precision Inc. is good to serve the smaller volume (lower than MOQ) by charging the additional cost of machine set up cost on die casting, CNC machining and coating.
General lead time: 1. Tooling lead time is 5-12 weeks. It depends on the components size and shapes. The bigger size and complex one normally will take longer lead time for tooling. Aluminum dies and magnesium die take the same lead time if the component is the same, zinc dies and plastic injection dies will take short lead time to compare with aluminum dies and magnesium dies.
2. Production lead time: If customers request raw casting parts after tool approval, the lead time is only 2 weeks. Most of designs request to be shipped with finish parts. It means the related post machining, painting/plating and simple assembling is required after casting. The manufacturing time is depending on subsequent operations, each of them takes certain time after casting. We normally ship finish parts by 35-40 days for your reference. We will always show our lead time for both tool and production on our quotation sheets to you.
Investment Casting (Lost Wax): The metal mold (normally aluminum mold) makes wax or plastic replica. They are sunk into investment material, or they are sprued with investment material. These replicas need to be dried out for few days, and then heated to melt down the internal wax and pour the wax out (lost wax). The replicas are baked to sinter them as the mold cavity. The requested metal is poured into the mold cavities. To break the mold shells and take the castings after the molten metal is cooling down.
Applied metals: Most of casting metals, we are skilling with aluminum alloy, brass, bronze, cooper, stainless steel and iron.
The size range of components: It could be casted from 1 ounce to 150lbs.
General tolerance of component: +/-0.003” to 0.25”; +/-0.004” to 0.5”;+/-0.005” per inch to 3”; +/-0.003” for each additional inch.
Minimum draft angle requirements: None. It don’t need draft angle because casting is obtained by breaking mold shells. The draft angle is used to help the components to be released from the steel dies. By the way, undercut design is castable by investment casting (Lost Wax).
Minimum section thickness: It is 0.040” for small areas. The larger areas should be thicker than 0.070”. Actually, it is not a good option for a component which request a lot of thin walls.
Minimum ordering quantities: It is a good option for aluminum casting which the volume is under 1,000 pcs. It will save cost from tooling. Usually, it tools the aluminum mold for wax replica. The aluminum mold is light and easy to machine to compare with die casting steel mold. The characteristic offer a possibility of replacement for die casting parts in smaller volume. It save tooling costs however it won’t save the component cost since the various casting procedures take more time and cost. For the other casting metals, we allow the reasonable small quantity from customers.
General lead time: 1. Tooling lead time is 2 to 3 weeks, however the samples lead time will take 5 to 15 weeks depending on subsequent operations. Production lead time is 6 to 12 weeks also depending on subsequent operations.
Permanent Mold / Gravity Casting: The molten metal is poured into cast iron molds by nature gravity. The molds are coated with ceramic mold wash. The mold cores can be steel, sand and sand shell or others. Gravity casting machine opens the mold after casting is cool. The operator takes out the casting, and the iron molds (left and right) are sunk into cooling fluid. The fluid is also with mold release agent, so that the next casting can ejector smoothly from the molds. The permanent molds can cast with sand cores to build the hollow middle for functional usage or cost saving. Gravity casting can cast larger size parts. The die casting machine has the maximum material load per shot, however the gravity doesn’t have the limitation. Some special shape only can be casted by gravity mold. Gravity mold is with longer tool life since it is a kind of low pressure casting process. The low pressure casting won’t damage the mold like die casting under higher pressures. Of course, the dimensional precision and wall thickness can’t be competed with die casting part which is made by high pressure. It is also an option of die casting when the order quantity is too small.
Applied metals: Most of casting metals, we are skilling with aluminum alloy, brass, bronze, cooper and iron.
The size range of components: It could be casted from few ounces to 110 lbs.
General tolerance of component: Aluminum: The basic is +/-0.015”. Add +/-0.002” per inch. If it is across parting line add +/-0.010” to +/-0.030” depending on size. Copper base is similar to Investment casting. Iron is +/-0.03” basic.
Minimum draft angle requirements: If it is none-ferrous we hope outside is 2° at least ( 3° is desireable) and inside is 2° at least (4° is desireable). If it is ferrous, we hope outside is 1° and inside is 5°.
Minimum section thickness: It is 0.100” for small areas, up to 0.188” or more for large areas. For copper base, it is 0.060”. Ferrous is 0.188” for small areas and 0.25” for normal thickness.
Minimum ordering quantities: It is 100 pcs to 1,000 pcs depending on size.
General lead time: 1. Tooling lead time is 4 to 6 weeks, however the samples lead time will take 5 to 16 weeks depending on subsequent operations. Production lead time is 6 to 12 weeks also depending on subsequent operations.
Sand Casting: The tempered sand and tiny cosmetic sand is poured and packed onto aluminum or wood pattern halves, then removed the sand mold from pattern halves. Normally, top sand half should combine with bottom sand half to form the mold cavity in sand mold. It builds with or without sand cored. Pour the molten metal into the sand mold to fill the cavity. Once the metal is cool down, we take out the castings by breaking the sand mold.
Applied metals: Most of casting metals, we are skilling with aluminum alloy, brass, bronze, cooper, iron and gray iron.
The size range of components: It could be casted from few ounces to many tons.
General tolerance of component: Non-ferrous is +/-0.03” to 6”. Add +/-0.003” per additional inch. Ferrous is +/-0.03” to 3”, +/- 0.05” from 3” to 6”. If it is across parting line add +/-0.020” to +/-0.090” depending on size.
Minimum draft angle requirements: Sand casting needs the draft angle 1° to 5°. The cores needs the draft 1° to 1.5°.
Minimum section thickness: Non-ferrous is 0.125” to 0.25”. Ferrous is 0.25” to 0.375”.
Minimum ordering quantities: 500 pcs at least.
General lead time: 1. Tooling lead time is 2 to 4 weeks, however the samples lead time will take 3 to 11 weeks depending on subsequent operations. Production lead time is 4 to 10 weeks also depending on subsequent operations.