Die Casting

Vendosmart’s vendors offer different types of top-notch  services. The benefits of opting for their services are cost-effective prices, accurately designed end product, expected production capacity and more. Our vendors are well-versed in manufacturing die-casting components from non-ferrous metals such as zinc, brass, aluminum and bronze alloys.

In addition and if found necessary, they also provide
secondary operations or rework on the die cast components which involve processes such as surface finishes, shot blasting, plating & painting and reheating of manufactured cast products.

What is

Die Casting?

In popular words, die casting is a fast-manufacturing process which can produce accurate non ferrous metal components by making use of reusable moulds. Of the other manufacturing methods, it is preferred in many industries as this process gives the rare option of creating intricate shapes, designs and sizes.

This process is used in many industrial sectors ranging from medical, FMCG,  automotive, electrical segments, and even aerospace. Usually, any type of die cast component goes for mass production with various metal alloys. The tools used in manufacturing are high quality tools, moulds and dies. 

Die cast components usually are medium shaped but with complex designs. But some may be different, ranging from minute to large size.

After getting moulded to the required shape and size, if needed, the components get reworked on CNC machining tools. This process is known as surface finishes where different types of processes are followed to get the end product as per your requirements. Some of them include shot blasting, heating, plating, texturing as well as painting.

Our Vendors Have Your Entire Requests Covered

Rapid Type Prototyping to Mass Production

Please note, the Vendosmart team verifies every vendor before they find a place in the buyer service list. So, every die cast manufacturer or vendor uses the latest industry software/equipment as well as mould tools to produce parts/components/products as per your need from the required alloys or other materials. Every vendor in Vendosmart does have the capability to quickly respond, manufacture prototype products and deliver them before the deadline.

Our vendor-manufactured products are tested for quality and then delivered. Though the die cast components have thin walls, they are stronger than parts manufactured from other methods.

Types of

Die Casting Processes

Vendosmart vendors are proficient in manufacturing components or parts from the two primary processes of die casting, namely, cold-chamber as well as hot-chamber. Their manufacturing units also use die casting technologies such as Gravity Die Casting (GDC), Low Pressure Die Casting (LPDC) and the last is High Pressure Die Casting (HPDC). Every process and technology will yield a different component of various strengths depending on the metal type, shape, weight, size and surface finishes. The most preferred type is, however, hot chamber casting. The charges of manufacturing a die cast from hot chamber casting are more when compared to cold chamber casting.

While pressure die casting uses force to work on a molten material into a mould, gravity die casting uses gravity to fill the mould. However, pressure die casting (low pressure and high pressure) is more preferred because the time duration is less. But when compared to gravity die casting, the production charges are more, as the process is more complicated and cannot be used for minimum manufacturing of components.

Our vendors can work across a variety of materials ranging from non-ferrous metals (copper, aluminum, magnesium, zinc) and alloys such as copper, zinc. Please note, their material selection is not limited to the mentioned materials as conveyed in the blog.

Reworking on the

Moulded Components

The term ‘rework’ in die casting is used differently such as finishing process, surface finishes, secondary operations etc. However, the reason is the same – the to-be-delivered product should match the buyer’s (your) need.

Finishing Processes

As the name implies, after the die cast components are manufactured, they have to be made perfect as per the need of the buyer. So, different processes are used such as thermal deburring, vibration model to remove the unwanted overflows, imperfections, burrs, gates and smoothen the surface.

Plating / Painting

It is easy to understand the benefits of plating, painting and also notice the differences between the two. Plating can change the surface of a die cast whereas a painting can make the exterior look attractive.

Surface Finishes

This process is opposite to secondary operations. At times, conversion coatings are required to cover surface impurities, imperfections and other types. Also, the surface finishes offer other benefits such as attractive appearance, preventing corrosion and promoting durability. Please note, for textured surface die-cast components, our vendors make use of the shot blasting process.

Secondary Operations

A buyer may request some components which cannot be produced by only die casting processes. In this case, after the production, secondary operations are done to design the areas, shapes and sizes as per the need. Usually, the processes involved are drilling, tapping, reaming etc. In normal cases, precision CNC machine tools are used to design the specific shape, size and dimension.

The popular examples of combined conversion coatings (plating and painting) when it comes to aluminum components are

When it comes to combined conversion coating for zinc, the most popular component is Chromate.

Cosmetic Finishes

If there is a requirement for a cosmetic finish, our vendors make use of powder or liquid to the surface, with various colour options. Please note, these components can have either a smooth, medium or rough surface finish.

The Last Part

The last process on the die cast component, involves testing for corrosion resistance (example – salt spray testing). There are also other types of testing such as pneumatic and hydrostatic pressure tests.

There are times when our vendors have gone out of their way to test parts (designed as per the need) in assembly segments of various industries. This process will involve acquiring a similar assembly set-up to ensure the recently designed die-cast components suit the requirements.

Our Experts Say

We understand that as a buyer, you will require a high quality service from our vendors. Yes, our vendors are known for delivering high quality components on time. Our vendors serve many industry sectors that demand the most accurate equipment components.

With Vendosmart, it becomes easy to find a verified reputed vendor who can provide unconditional and unlimited support when it comes to manufacturing die casting components of various production capacities, shapes, materials, surface finishes and other services. We welcome you to join the unlimited list of buyers who have found their right die casting service providers via Vendosmart.

The printing industry expanded its capabilities in the mid-1800s. This was mainly due to die casting equipment. Each mobile typing machine needed punctuation marks, letters (many types) and other symbols. Manufacturers used this new method to speed up the creation of individual elements. With die casting technology, they can produce elements of uniform sizes. Early printing machines used the same to reduce step-up times & errors.

Die Casting Process

Reference: Wikidemia.org

In die casting, the liquid melt gets pressed into a mould at high pressure. The high pressure bars vary between 150 to 1200. Speed also occupies a major factor (up to 540 km/hour). Usually, the materials used are low melting alloys. Die casting differs from sand casting as permanent metal moulds get used in the process. Unlike sand casting, the moulds need not be destroyed. So, manufacturing companies use die casting process for mass production of components. Die cast mould walls have low thickness. So, it is possible to manufacture large and complex components.

The following are the steps involved in die casting:-

Step 1: Preparation

Preparing the die is the first step in die casting. The die casting mould gets heated to a suitable temperature. Then, a refractory coating or lubricant gets sprayed onto it. This lubricant helps maintain the temperature of the die during the manufacturing process. The other benefits – it prevents premature solidification and assists in removing the cast once it has set.

Die casting engineers then use a high-pressure clamp to close and secure the die halves together.

Step 2: Injection

This is the second stage. The molten metal is taken from a furnace and poured directly into the die via a downward sprue. As per the need, manufacturers use either manual or automated process. Both the processes use gravity and other forces/pressures are not used. Liquid gets inserted in a straight  vertical position into the die. It naturally falls into the mould due to the natural pull of gravity.

The use of low-pressures eliminates turbulence and, as a result, leads to smoother components and parts. This, in turn, reduces porosity.

Step 3: Cooling

Having inserted the molten metal into the mould, it is then allowed to cool and solidify. To unclamp the die, the metal must have had sufficient time to take the shape of the mould. It must also be completely set before it is unclamped. The cast can be irreversibly damaged if it is removed prematurely.

Step 4: Ejection

Die cast engineers allow a certain amount of time before checking the die halves. Then, they are unclamped and opened, and the cast parts are carefully removed. You can either do this by hand. In some cases, ejector pins get used to safely remove the cast from the gravity die casting machine.

Die casting

Reference : rocheindustry.com

Step 5: Trimming

Trimming is the last step in gravity casting. The metal has to get cooled to the required temperature. Then, the gate, runners, sprues, and flash are expertly removed from the casting. A variety of tools get used to remove any sharp edges and excess material. This is to create the desired shape of a component as per the client instructions. The part is usually cleaned before despatching to the customer.

Advantages of Die Casting

Die cast parts get produced from moulds. So, they can be produced within specified tolerances and shapes. Thousands of identical castings get produced. There are few chances of needing tooling or machining to produce the desired shape. This makes mass production an easy process.

With diecasting, manufacturers can produce parts that have excellent durability and are dimensionally stable. These parts, in addition to having heat resistance also have tight tolerances.

Die cast parts have more strength and weight than injection molded plastic parts of the same dimensions. In contrast to other casting methods, thin wall castings are stronger and lighter. The major benefit in this process is die castings are not made up of parts that are welded or fastened together. Their strength is derived from the alloy itself rather than the joining process.

Applications of Die Casting:

The die casting process is used to produce parts with complex shapes, precise dimensions and clear outlines. In addition, the parts have very high surface quality, strength, and hardness. So, it is widely used in various industrial sectors. Among the many uses of die-casting is the production of consumer goods. Die-casting parts are used in the manufacturing of automobiles to the tune of 60%. The die-casting process is also used in various parts of Mercedes-Benz cars.

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