Die Casting FAQs

Die casting CWM Die Casting Plant  是一种定制制造工艺,通过在非常高的压力下将熔融金属注入可重复使用的模具来生产工程金属零件, called “dies,” made from premium tool steel. 模具可以被设计成铸造非常复杂的形状和清晰定义的产品特征,具有高度的精度和重复性, 通常不需要进行铸造后加工以满足零件规格要求. 铸造时可以产生异常光滑的表面,以及各种纹理表面. Die castings are suitable for a range of cosmetic finishes to match other mated parts or add extra durability in use. Advanced high-pressure die casting, 有些机器的锁模力超过每平方英寸4500磅, 是否能够在非常高的循环速度下生产高完整性和尺寸精度的净形或近净形铸件. 一个完整的压铸周期可以从小于一盎司的小部件的不到一秒变化, 几磅重的石膏不超过两到三分钟. 该工艺的优点使压铸成为最有效的技术,可用于生产广泛的商业, industrial, and consumer products in durable, rigid metal. A range of metals can be die cast, but the majority of die castings are non-ferrous parts, in aluminum, magnesium, and zinc.

On the one hand, 压铸件具有重力铸造件的许多品质:刚性, look and feel of solid metal; documented fatigue strength characteristics; excellent sound-damping properties; inherent EMI shielding for electronic applications; and part serviceability and recyclability. Unique to the advanced die casting process, 哪个公司使用高压力和高温,用优质钢模具铸造最复杂的零件细节, 铸件可以快速和一致地生产,以接近公差, often eliminating all machining. 砂型铸件每一个铸件或铸件门都需要一个新的砂型. The permanent mold gravity process uses iron or steel molds, but, like the sand process, is far slower and less precise than die casting. 高科技压铸可以产生最高质量的表面抛光, as cast, and parts can also be designed with inherent bearing properties.

High pressure casting and high-pressure die casting are terms used in Europe and countries other than the U.S. for what is referred to in the U.S. simply as the die casting process. 低压压铸和重力压铸是在美国以外使用的术语.S. for what in the U.S. 叫做低压永久模和重力永久模铸造. Although they each use metal dies, 由于涉及较低的压力,它们被限制在较重的部分, 通常会导致更高的成本,因为合金的使用效率较低,加工时间较慢. 它们还需要在模腔上喷涂一层保护涂层, which means looser tolerances and rougher surface finishes.

The casting industry generally has applied the word “miniature” to miniscule zinc die castings 采用专门的热室生产,产量高,成本低, high-speed die casting machines (4-slide machines, for example) that yield castings which are flash-free. Parts can be cast in Zn 2, 3, 5, and 7, and now in higher-strength ZA-8 hot-chamber alloy, with zero draft and to very close tolerances. 这些部件通常不需要修边,通常也不需要铸造后的加工操作. Mini die castings can be produced on larger, conventional die casting machines using multiple-cavity dies. However, 四滑轨设备往往是铸造净形无闪件的最佳方法, 非常小的锌零件以最低的零件成本和最小的模具投资. Newer equipment has brought the advantages of miniature die casting to larger part sizes, up to .75 lbs.

Metal matrix composites (MMC) 大部分的铝基合金都有高达20%的碳化硅(SiC)颗粒增强吗. 用这些材料制成的ASTM试验样品的机械性能通常匹配或接近铸铁和钢的许多特性, at a lighter weight. 性能可以超过大多数铝,镁,锌,或铜元件通常生产的压铸. Al MMC parts offer higher stiffness and thermal conductivity, improved wear resistance, lower coefficient of thermal expansion, reduced porosity, and higher tensile and fatigue strengths at elevated temperature, with densities within 5% of Al die casting alloys. Al MMC alloys can be cast on conventional die casting 机器,但可用的定制压铸生产仍然是有限的.

 

挤压铸造是近年来引进的一种高压铸造工艺, through the use of very large gates and high hydraulic pressure, 铸造液态金属时,紊流和气体夹闭是否最小. The result is a porosity-free, 厚壁可热处理部件,能够通过汽车结构件必不可少的关键功能测试. Production costs will be higher than conventional high-pressure die casting, 但在高强度的应用中,挤压铸造零件有资格取代永久性模具和铸铁铸件. Most production to date has been made with aluminum alloys. 利用挤压铸造机的脚轮数量相对有限.

This semi-solid metal casting process (SSM) 使用一种特殊的铸坯,在特殊的铸造机上切成加热的铸坯. The uniform, 加热段塞的球状半固态组织提供了能够在高压下填充铸模的流动特性:基本上消除了气体滞留,减少了凝固收缩. 汽车结构件的早期鉴定是成功的. 该工艺可以铸造比挤压铸造更薄的壁,并已证明适用于铝和镁合金. 生产成本高于传统高压压铸件, with available production facilities still limited.

触控模塑是一种触变性半固态合金注塑成型的净形或近净形零件. 当加热到接近熔点和施加剪切力时, certain metal alloys exhibit thixotropic properties, 变成半固态物质,其中固体颗粒悬浮在液体基质中, allowing the viscous metal material to flow. 工艺的局限性常常使其难以精确地塑造产品设计中所要求的某些复杂的净形状特征, which can be produced by advanced die casting technology. 使用触控模压机的生产商数量仍然有限.