Superband high pressure die casting services produce geometrically complex castings, primarily from aluminiuma alloy and zinc. The production process allows thin walls to be created within castings that are strong and have excellent surface finishes. Superband high pressure die castings are used to produce a variety of components including pump housings and valve components.
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The process
The “cold-chamber” high pressure die casting process
High pressure die casting (HPDC) can be divided into “cold-chamber” and “hot-chamber” processes. Hot chamber HPDC is used mainly with low melting point magnesium and zinc alloys whereas cold chamber HPDC is most commonly used with aluminium alloys.
In the cold-chamber process:
Molten metal is injected into a cold chamber for each machine cycle (or shot).
The molten metal is forced by a single plunger through a narrow feeder channel (or gate), into the die cavity, by the application of pressures ranging from 1500 to 25,000psi.
The die is water-cooled so the casting cools rapidly, usually within a fraction of a second, while pressure is maintained until solidification.
Once solidified, the dies are opened and the casting is removed using ejector pins. Most castings will have flash where the two die halves come together, which is usually removed in a trimming die.
In the cold-chamber process:
Molten metal is injected into a cold chamber for each machine cycle (or shot).
The molten metal is forced by a single plunger through a narrow feeder channel (or gate), into the die cavity, by the application of pressures ranging from 1500 to 25,000psi.
The die is water-cooled so the casting cools rapidly, usually within a fraction of a second, while pressure is maintained until solidification.
Once solidified, the dies are opened and the casting is removed using ejector pins. Most castings will have flash where the two die halves come together, which is usually removed in a trimming die.
In the hot-chamber process:
A gooseneck shot sleeve is submerged in a heated pot of molten melt.
A plunger descends and forces the molten metal into the die.
Once cooled, the casting is ejected by ejector pins.
As the piston retracts, the cylinder is filled with metal and the process repeats.
Why use Superband High Pressure Die Casting?
High pressure die casting delivers many benefits including:
The capability of casting large quantities
The ability to cast complex shapes quickly and accurately
Castings are high strength
Surface finishes can be exceptionally good
Production rates are rapid
Production lines are not labour intensive
Scrap metal can be recycled
Conclusion
The High Pressure Die Casting Mold is a vital component in the production of high-quality, precision-engineered castings across various industries. Its ability to produce components with tight tolerances, rapid production rates, and material versatility makes it an essential tool in modern manufacturing. However, overcoming challenges related to mold complexity, wear, and material selection is crucial to maximizing the process's efficiency and effectiveness.
