The development advantages of light alloy die casting industry

    Light alloy die casting industry conforms to the development trend of energy saving and consumption reducing. Such as light alloy has the advantages of lightweight, can reduce the car's weight and energy consumption. Light alloy casting with no cutting process, the use of resources recycling, environment friendly technology. The increasing demand for light alloy for electronic products. Lightweight, intelligent development trend of consumer electronic products, light alloy consumption will maintain a rapid growth rate for consumer electronics.
    Cost advantages make light alloy die casting industry is developing rapidly. Light alloy die casting have a variety of preparation process for electronic products. Among them, the aluminum alloy cold forging +CNC integrated molding process, performance advantages, but the cost is high, and the remaining capacity of the supply chain is insufficient. Light alloy die casting technology has a cost advantage, high production efficiency, supply chain capacity is enough. But the die casting products surface treatment effect is poorer, other performance also varies. In the low-end product market competition has become the main battlefield of consumer electronics, forcing manufacturers of electronic products around cost competition. Light alloy casting cost advantage, and it has thin and light performance characteristics, will win more and more market.

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The basic principle of die casting mold making design

    1. To fully understand the relationship between the use of castings and other structural components. When the die casting mold making design, according to the structure and performance of die castings to prioritizing, focus on mold structure and mold process according to the type of processing, reasonable selection of mold surface, cavity number and layout, die casting parts mould release method.
    2. Understand the actual processing capacity of mold. To meet the actual mould design according to the existing technical level of equipment and operating personnel.
    3. To meet the requirements of the mould die casting production process. In accordance with the process requirements of the casting pouring system and exhaust system. Especially the location of the internal gate, the internal gate speed and flow direction, to make the liquid metal flow is stable and smooth and orderly removal of gas cavity, in order to achieve good filling effect and avoid casting defects.
    4. Die casting mold design should meet the requirements of machining process and heat treatment process.
    5. To fully consider the mold temperature change with the precision influence on sliding parts.
    6. Find ways to improve life of die.
    7. Install the mold should be convenient and reliable.
    8. The die casting mold making design to allow sufficient repair modulus.
    9. Die casting mold making as far as possible the use of standardized, universal parts to shorten the production time.

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The processing requirements of drawing metal stamping parts

    Metal stamping is a widely used product in our daily life. With the development of science and technology, people more and more requirement of metal stamping parts. Especially in terms of quality and technology requirements are very high.
    The drawing metal stamping parts requirements:
    Drawing parts the shape should be simple, symmetrical, the depth should not be too large. The drawing number is minimal, easy forming.
    The drawing radius does not increase in process conditions. Otherwise it will increase the number of drawing and shaping work, also increased the number of molds, and easy to produce waste and improve cost.
    Metal stamping parts quality requirements are very strict, so the metal stamping parts supplier must strictly control the shape and size of stamping parts.

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Precision die casting parts manufacturer of production notes

    Precision die casting parts manufacturer need to pay attention to the following several points in the production process:
    1. From the beginning of the procurement alloy ingot, the supplier must have strict standards for components. High quality alloy material is the production of high quality castings guarantee.
    2. Alloy ingot stacking area to ensure clean, dry, to avoid long time exposure to moisture and generated white rust or be dirt pollution of the factory, otherwise it will increase the loss of metal. The clean factory environment is very useful for the effective control of the alloy composition.
    3. Ratio of new materials and returns, returns no more than 50%, new materials : old material =70:30. Continuous remelting of the important elements in the alloy decreased gradually.
    4. When drainage opening material was remelted, must strictly control the remelting temperature of not more than 430 °C, in order to avoid the loss of alloy elements.
    5. When remelting cannot have the tin galvanizing, the soldering tin and the lead polymer.
    6. If the condition allows, die casting parts manufacturer can be used to centralized furnace melting alloy material, the alloy ingot and the returns ratio is uniform, the flux can be effectively used, the alloy composition and temperature uniformity and stability. Electroplating waste and fines should separate melting.

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The reason of zamak die casting parts have holes

     The holes are two kinds of zamak die casting parts, mainly is the blowhole and shrinkage hole, the blowhole is often round, and shrinkage hole mostly irregular.
         (1) the blowhole cause: the liquid metal in the mold filling, solidification process, because the gas invasion, leading to the casting surface or internal holes. or is out of the volatile gas of coating. or the alloy liquid gas content is too high, the coagulation precipitation. When the mold exhaust is not good, these adverse factors will lead to the formation of pores of zamak die casting parts.
         (2) the shrinkage reasons: the solidification process of liquid metal, because of the volume reduction or the final solidification position not feeding of molten metal and the shrinkage hole. Casting uneven thickness or local overheating, causing a slow solidification position, volume shrinkage is formed on the surface of the concave position.
         If the zamak die casting have the blowhole and shrinkage hole, on surface treatment, hole may enter the water, when the painting and plating after baking, hole gas heating expansion; or hole internal water becomes vapour, volume expansion, thus lead to the casting surface blister.

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About magnesium die casting material stickness

         Die cast alloy stick refers to adhere to the walls of the mold cavity. This phenomenon is a great influence on the die casting process.
         The solubility of die material in the molten alloy. Magnesium alloys have an advantage in this regard. The main alloy elements of die steel are insoluble or slightly soluble in magnesium alloys, such as iron, cobalt, manganese, aluminum, calcium, in addition to the nickel. So magnesium die casting material don't sticks mold.
         The strength of castings in the ejection temperature. About 300 °C, The strength of the magnesium alloy is about half of the aluminum alloy, As long as the cavity surface is no problem, the launch is balanced, no shear stress, sufficient to ensure the castings mould relese in this hot strength.
         Adhesion coefficient between the casting and the cavity surface. When the roughness between rubbing surface is 30/um and the rubbing speed is 0.1m/s, the adhesion coefficient between aluminum and steel is 0.1, while the adhesion coefficient between the magnesium and steel is 0.05. So magnesium die casting can use minimum demoulding inclination, and can obtain higher accuracy.

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The characteristics of China die casting manufacturer

      The one of the characteristics of China die casting manufacturer is the application of a wide range of die casting products. In Japan and the United States, the proportion of automobile die casting up to 80%~90% in die casting total, but only about 50% die castings in China. Die casting products, another part is used in motorcycles, agricultural vehicles, electric bicycle. This greatly reduces the influence of automobile market for die casting market.
      In China, die casting manufacturer the service object and the proportion: Automobile and motorcycle is 62.8%; the hardware and toys accounted for 16%; electrical and electronic products accounted for 11.8%; general machinery and other industries accounted for 9.4%.

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Zinc alloy die casting parts should pay attention to the problem

         Attention should be paid to the use of zinc alloy die casting parts process problems:
         Poor corrosion resistance.  When the impurity elements of lead, cadmium and tin to exceed the standard in the alloy, leading to the casting of aging and deformation, showed the volume swell, the mechanical properties decreased significantly especially plasticity, the long-term use possibly can rupture. Lead, tin, cadmium solubility is very small in the zinc alloy, so focus on the grain boundary and as cathode, high aluminium content solid solution as the anode. The water vapor (electrolyte) under the conditions of existence, to intergranular corrosion. Die casting due to intergranular corrosion and aging.
         Timeliness. Zinc alloy microstructure is mainly composed of zinc solid solution contains aluminum and copper and aluminum solid solution contains zinc. Their solubility decreases with the temperature decrease. But because the pressure of the solidification of the casting speed, therefore to room temperature, the solubility of solid solution is saturated. After some time, the saturation phenomenon will gradually lifted, and the shape and size of the casting is slightly change.
         Zinc alloy die casting is in high temperature and low temperature (0 DEG C) use of working environment. Zinc alloy has better mechanical properties at room temperature. But in the high temperature tensile strength and low temperature impact properties were significantly decreased.

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Application of aluminum die castings

     Aluminum and aluminum alloy has good fluidity and plasticity, so it can be made into various shapes of complex aluminum die castings. Aluminum or aluminum alloy casting parts with high precision and surface finish, which reduces the amount of mechanical processing of castings in the very great degree, and greatly reduce the amount of labor, but also save electricity and metal materials.
     Because of intrinsic quality and external quality is high, aluminum die casting is widely used in automobile, internal combustion engine production, motorcycle manufacturing, motor manufacturing, transmission machinery manufacturing, precision instruments, landscaping, construction, electric power and other industries, to become the new darling of the die casting industry.

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The formation reasons of magnesium alloy die castings porosity

    The formation reasons of porosity of magnesium alloy die castings, one is  because the gas is separated from the liquid during the cooling process, mainly hydrogen, the other is into the air in the casting process. The ability of magnesium dissolved hydrogen is very strong, even if only a very small amount of water in the ingot, may also be because the water is reduced and the absorption hydrogen. However, the nitrogen generating nitride, oxygen to produce oxide. Therefore, the effects of air is smaller, The temperature of the air is concerned with the gas content, so the magnesium alloy die casting materials must be thoroughly dried before they can cast furnace melting.

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What are the light alloy die casting materials

    According to the different raw metal of die-casting, light alloy die casting materials can be divided into aluminum alloy die casting, magnesium alloy die casting, zinc alloy die casting, copper alloy die casting and so on.
    Aluminum alloy is light, good abrasion resistance, high mechanical strength, good heat and electrical conductivity, and can withstand high temperatures, which are widely used in automobile, communication infrastructure. At present, aluminum alloy die casting production is the highest in the non-ferrous metal die-casting.
    In the commonly used die casting alloy, magnesium alloy is the lightest metal, widely used in 3C products, auto parts and electric tools.
    In the three kinds of non-ferrous metals, zinc alloy is the most easily die casting. It has high toughness, high impact strength and easy electroplating etc.. It is used to Home Furnishing products, 3C products, construction equipment, toys and car parts.

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The development of die casting mold making in China

    Middle period of 1990s to now. The rise of China automobile manufacturing industry, and the rapid development of the world of the technology of the mould, die casting mold making in China industry has been leaping development. Die casting die manufacturing technology of motorcycle parts is becoming more and more mature, large and complex auto parts mold research and development, manufacturing, mold development to the large-scale, complex, the long life.
    Especially in the last two years, the appearance quality of widespread attention and the service life of the die has been significant progress. Application and popularization of CADl / CAM technology, the individual enterprise also uses CAE to carry on the flow and thermal field analysis, the first hardening and then finish machining process is widely used, utilizing three coordinate measuring instrument detection size, assembly, repair the mold in the mold closing machine, application of vacuum gas quenching and other advanced equipment and technology. During this period, basically choose domestic or imported H13 type steel, the mold can be applied to the die casting machine is less than 35000kN, large die can weigh up to 20 ~ 30t.
    At present, die-casting mould of household electrical appliances, motorcycles and other industries can fully meet the needs of the automotive industry, the proportion of domestic die-casting die is more and more big, magnesium alloy die casting mold began developing. During this period, China imports of many large, precision, complex die casting die, at the same time China die casting mould began to export to foreign countries, some enterprises production molds are exported to the advanced industrial countries.

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