Effect of melting temperature on zamak die casting

     The best melting temperature on zamak die casting: the melting point of zinc alloy for die casting is 382 ~ 386 °C, and the suitable temperature and low temperature control is an important factor for the zinc alloy composition control. In order to ensure the liquid alloy with good liquidity, zinc pot temperature of molten metal is 415 ~ 430 °C, thin wall and complex die casting temperature desirable upper limit; wall thickness and a simple desirable lower limit value. The temperature of metal liquid in the central smelting furnace is 430 ~ 450 °C. Enter the gooseneck liquid metal temperature and the temperature is almost the same as the zinc pot. By controlling the temperature of the zinc pot, the casting temperature can be accurately controlled.

    When the melting temperature is too low, the flow property of the alloy is poor, which is not conducive to the formation, which affects the surface quality of the zamak die casting.

    The melting temperature is too high, the reaction of iron crucible and zinc liquid is accelerated, the crucible surface oxidation reaction to produce Fe2O3 and other oxides; iron element also reacts with zinc to produce FeZn13 (zinc dross), and dissolved in the zinc solution. The aluminum and the magnesium element burning loss, the metal oxidation rate speeds up, the burning loss quantity increases, zinc dross increase. Thermal expansion occurs card die hammer phenomenon. The iron element in cast iron crucible is more and more, and the reaction of zinc and iron at high temperature is accelerated. Hard particles can form Fe Al compounds, causes the hammer head and the goose neck excessive wear. The iron element in cast iron crucible is more and more, and the reaction of zinc and iron at high temperature is accelerated. Hard particles can form Fe Al intermetallic compounds, the hammer, gooseneck excessive wear. Fuel consumption increases accordingly. The higher the temperature, the casting crystallization is greater and reduce the mechanical performance.

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Development trend of magnesium die casting for auto parts

    Because magnesium alloy has a series of advantages such as low density, high strength and stiffness, good anti corrosion and anti electromagnetic radiation ability, good filling performance and renewable utilization, it is more and more application in automobile, electronics, home appliances, communications, instrumentation and aerospace, etc..
    The application of magnesium die casting for auto parts in the developed countries has continued to grow rapidly, such as Europe, America, Japan, etc.. According to the International Magnesium Association (IMA) estimates, with the development of the world automobile industry, the demand for magnesium alloy die casting will continue to grow. It is estimated that by 2030 the world's total car will be more than double, reaching one billion. In the next 10 years, the demand for magnesium in the automotive industry will increase by 15%.
    Into twenty-first Century, magnesium die casting for auto parts will become the most important application areas of magnesium. The developed countries in Europe and the United States of automobile light weight, less fuel consumption, meet the environmental requirements of the rapid growth of magnesium die casting. In addition, magnesium alloy die castings can also improve the structure and dynamic performance of the car. which is also one of the reasons for the automotive industry to pay attention to magnesium alloy.

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The problem faced by die casting manufacturer in China

   At present, the problem faced by die casting manufacturer in China are as follows:
   First, the contradiction between the internationalization of the die casting Market and the quality of the enterprise. The world non-ferrous casting production core shifts to China. However, due to the level of the die casting process, the technical equipment and the quality of the enterprises have a gap compared with the international advanced level, need to have a process to improve and perfect. At present, the export of die-casting products to middle and low priority, especially in the low-grade. We should actively improve the quality of enterprises, enhance the technical capacity, increase the added value, to achieve industrial restructuring, and gradually developed into a modern die casting industry.
   Second, the rapid development of die casting manufacturer and ecological environment. Die casting enterprise development is very uneven, some of the enterprise's environmental protection and labor health care is better; but some of the production conditions are very poor, environmental pollution is serious. Pay attention to the ecological environment, caring for the health of workers, strengthen environmental management, to improve the labor health, rigorously enforce the clean production, the development of circular economy. This is the only way that China die casting manufacturer sustainable development.
   Third, the contradiction between the cost of the enterprise and the profit space narrowing. Because of rising material prices, the casting price drops, the cost of labor increases, factors and so on environmental protection investment increase, the profit space reduces day by day, this brings the huge pressure for the die casting manufacturer.

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Why does zinc die casting have porosity

    Zinc die casting have porosity is often related to raw materials or smelting process.
    The main component of the gas is hydrogen in liquid zinc, which accounts for about 85% of the total amount of gas. Melting temperature is higher, the solubility of hydrogen in liquid zinc is higher, but the solubility of hydrogen in solid zinc is very low, so the formation of hydrogen in the solidification process is the porosity.
Source of hydrogen: water vapor in the atmosphere, liquid metal absorbed from the moist air. Zinc die casting raw material itself contains hydrogen, alloy ingot surface is moist, recycled scrap is dirty and greasy. The tools and flux is moist.

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The flow mark of aluminum die casting

    Characteristics: on the casting surface has with the molten metal flow direction consistent stripe. Stripe and metal matrix color is not the same and no direction, no development trend.
    How does the flow mark of aluminum die casting be formed?
    First, the molten metal into the cavity to form a very thin and incomplete metal layer, afterwards comes in the molten metal to make up for it and formed flow mark; mold temperature is too low and uneven; the ingate sectional area is too small and improper location result liquid metal spray; the pressure on the liquid metal is insufficient; coating dosage is too much.
    Processing method:
    Improve the temperature of a molten metal to 620 ~ 650 °C; improve the aluminum die casting mold temperature, maintained at a temperature of 200 ~ 250 °C; increase the ingate sectional area and change the inlet position; adjustment of the filling velocity and injection time and the length of the flow channel; selection suitable coating and adjust dosage.

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The market share of light alloy die casting

    In developed countries, the market share of light alloy die casting is relatively high. With the increase of the die casting equipment and technology, more and more black metal castings are replaced by the nonferrous metals die castings, such as aluminum alloy and magnesium alloy. At present, the production and consumption of the die casting of the country is mainly the United States, China, Italy, Germany, Mexico, Japan, etc.. In developed countries die casting industry, individual enterprises of large scale, specialization degree is high, high degree of concentration, in the capital, technology, customer resources and has strong advantages, higher value-added products, the proportion of market share higher.

    Our country's pressure casting market share is in the stable growth phase. In the past ten years, the annual growth rate remained at 10%. The market share of high precision aluminum alloy die casting is higher, magnesium alloy die casting market share in the steady rise stage. Aluminum alloy, magnesium alloy and other light alloy die casting industry is the basic industry of national economic development, product application field is very extensive.

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Design principle of die casting mold horizontal runner

    The structure and size of the die casting mold horizontal runner is determined by the structure, location, direction and the width of the inlet port.

    The cross-sectional area of the horizontal runner is greater than that the cross-sectional area of the ingate in any case. If it is multi-cavity mold, the cross-sectional area of the main runner should be greater than the sum of the cross-sectional area of the branch runner.

    The horizontal runner should have a certain thickness and length, to ensure the steady flow and the guiding role of liquid metal. The corner should take a circular arc. Too thin will cause the loss of heat, is not conducive to pressure transfer and repair. Too thick will increase the consumption of materials, reduce the production efficiency of die casting. In the die casting mold making, in order to save material and reduce the flow resistance, the horizontal runner should be as short as possible.

    From the straight runner end to the ingate, the cross section area of the horizontal runner should be maintain consistent or slow contraction, can not suddenly change, to prevent the negative pressure suction or package gas.

    Die casting mold for horizontal cold chamber die casting machine, in general, the horizontal runner entrance should be located at the top of the straight runner, to avoid the liquid metal in the pressure chamber into the mold cavity before injection.

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How to develop metal stamping parts manufacturers

    Hardware stamping parts have become the future development opportunitie of hardware market. With the automatic lathe parts market competition pressure increases, most metal stamping parts manufacturers in the production, the different stages of the industrial chain of profits are to reduce, the price of space decreases with each passing day. According to the international mould and hardware plastic Suppliers Association survey found that, after price increases, increases the cost of hardware factory, if rely on their own to support, is difficult to transfer to the downstream, metal stamping parts supplier profits further squeezed. The industrial chain develops the vicious circle causes the multitudinous hardware factories realized that wants the long-time development, must choose the new market. At the same time, only by price competition can not establish the core competitiveness, this is not a long-term development direction, so to explore new development path. At the same time to strengthen the enterprise's own product technology innovation and quality improvement. To establish a new management principle, to ensure the sustainable development of enterprises.

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Market space for die casting parts manufacturer

    The market space for die casting parts manufacturer generally includes automobile and transportation facilities, construction and residential products industry, instruments and apparatus, electric power and telecommunications industry, electronic computer equipment and other etc.. The output of Chinese die casting is increasing year by year. Since 2001, the annual growth rate has reached 13.25%.
At present, China's auto industry is in a rapid growth period, the scale effect is beginning to show. The correlation degree between the die casting industry and the automobile industry is mainly concentrated on the production of the car. This structural change of China's automobile industry, which gives the die casting industry a more broad space for development.
    At the same time, in some industrialized countries, industrial structure of die casting production appeared a fundamental change, enterprise of a few die-casting experienced Association, merger and reorganization, and even some failures, and part of the enterprise will die casting production transferred to overseas, and set up another factory.
    For example, the number of die casting parts manufacturer has been decreasing year by year in the United States, but the demand of the pressure casting has not declined, especially in the automobile industry. To meet this demand, the country or by set up factories overseas production die castings, or to purchase from overseas, the target area is mainly concentrated in South America, Europe, East Asia and Southeast Asia area.
    Other countries have similar tendencies and behavior. According to foreign media reports, some of the international giants of the auto industry made it clear that the intention to buy auto parts, parts and vehicle from china. Domestic media have also reported that the purchase of foreign buyers from China to buy auto parts, from hundreds of millions to billions of dollars. This is bound to provide greater market space for the die casting industry.

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Why there are bubbles in the process of zamak die casting

    The cause of the bubble is related to the parameters of die casting process and the structure of the mold in the process of zamak die casting. Due to the pressure chamber, the gating system, the mold cavity are communicated with the atmosphere, and liquid metal is with high pressure and high speed filling, if you can not achieve the orderly and steady flow state, liquid metal produce eddy current, resulting in the air enters the mold cavity.
(1) The liquid metal can cleanly and smoothly flow in the gating system, and does not produce separation and vortex.
(2) If there was a sharp or dead zone?
(3) Does the cutting area of the gating system change?
(4) Is the location of the vent and overflow groove correct? Is it big enough? Whether it will be blocked? Can the gas discharge effectively and smoothly?
The application of computer simulation of zamak die casting filling process is to analyze the above phenomena, and to make a reasonable choice of parameters.

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The crack defect of magnesium die casting

    The crack is irregular and filamentary crack on the smooth surface of the castings. It is deep in the casting, sometimes even penetrate the entire casting. There are two kinds of crack defect of magnesium die casting is more common, one is the crack is produced under the external force, the other is the shrinkage cracks when casting shrinkage. The shrinkage crack is usually along the grain boundary, and its color is a bit dark under the microscope. The crack is produced under the external force is likely to penetrate the grain, and its color is bright under the microscope.
    The causes of the defects:
Melt containing impurities;
The protective gas is not sufficient;
Mold temperature is too low;
Improper use of release agent type;
The geometry of the die element is impaired;
The ejection position and configuration is inappropriate;
The casting geometry shape design is not good.
    Magnesium die casting have crack is often because of poor filling. Rhyolite is a potential source of crack. When casting is shrinkage or ejection, the casting will be fracture along the site of poor bonding. Some cracks appear to look like crack defects, but in fact, because of the melt flow is poor and lead to the non filling situation.

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The development direction of auto parts die casting manufacturer

     In the die casting industry some of the high technology are developed by the high requirements of the automobile industry. The auto parts die casting manufacturer should be to high-tech development. Including: power, transmission, steering, body, frame, decoration, instruments and other various system requirements of parts, some of these parts are structural parts, the mechanical parts, the safety parts, and the decoration pieces. For example: the use of whole set of 390 aluminum alloy die casting technology to produce full-aluminum cylinder block, the method of setting the cast iron sleeve in the cylinder barrel of the aluminum alloy cylinder body is abandoned. Uses the SF36 aluminum alloy manufacture automobile body frame connector, changed the automobile body traditional manufacture method. Titanium aluminum alloy (TIAI)  die casting automobile valve, opened a new field of titanium alloy die casting technology. Aluminum alloy die casting of diesel engine shell has been published in recent years.
     In recent years, the application of computer simulation technology in die casting is becoming more and more widely, which can improve the production efficiency of the die casting manufacturer, and expand the application scope of the pressure casting. Most of these techniques are first appeared in the automotive manufacturing industry. This fully reflects that the die casting process has a very broad market space in the automotive parts manufacturing industry.

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The influence of zinc die casting pouring system for filling conditions

    In die casting process, metal liquid filling type state is formed under the joint action of the factors in the pressure, speed, time, temperature, exhaust and so on. So zinc die casting pouring system with stress transfer, fund flow velocity, filling time, coagulation time, mold temperature, exhaust conditions have a close relationship.

    Stress transfer, on the one hand to ensure the metal liquid with high pressure, high speed filling cavity, on the other hand, but also to ensure liquid metal to different solidification in the flow channel and the nozzle, in order to guarantee the transmission pressure. This requires the channel and outlet design best, minimal pressure loss.

    Nozzle area is too large or too small will influence the filling process, too large gap filling speed was low, metal premature solidification, even filling not foot, too small nozzle makes the jet intensifies, increase the heat quantity loss, produce vortex streets and involved in too much gas, shortening the service life of the mold.

    Gas discharge is mainly determined in metal liquid flow moving speed and image flow direction, and row overflow system whether can make the gas discharged smoothly, exhaust area is sufficient or not. The exhaust is good or bad, will directly affect the shape and intensity of zinc die casting parts.

    Mold temperature due to the control on the casting quality is produced great influence, and impact on the production rate was efficiency, reasonable design of the nozzle can play a regulatory role on the mold temperature due to distribution.

    Mold life depends on a good steel and working state. Good zinc die casting pouring system design is to make various parts of mold heat balance in the best state, so as to get the maximum economic benefits of die casting production.

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