Custom Die Casting Manufacturing Company
Transcend Chrome Inc. has been providing high-quality die casting services for more than 30 years. We manufacture custom metal die-cast parts to companies in a variety of industries.
Introduction to Die Casting
Die casting is a metal casting process that involves pushing molten metal / liquid metal into a metal mold called a “die.” Die casting is one of the most used methods for producing parts with high dimensional stability for a variety of applications. Almost every industrial business relies on the advantages of die casting for various components including everything from impellers to heat sinks.
What Is Die Casting?
While die casting parts involves higher initial costs compared to some casting methods, it tends to result in lower per-unit costs for high-volume production. Other advantages of die casting include smooth surface finishes, corrosion resistance, the ability to produce complex shapes and durable products, and a reduced need for some secondary machining processes.
The two types of die casting machines are cold chamber die casting and hot chamber die casting machines.
The Die Casting Process
The die casting process involves multiple steps. Here’s a step-by-step look at the die casting process:
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A steel mold must be made into two (or more) sections to allow for the removal of castings.
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This mold can produce thousands of castings quickly in succession.
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After being securely mounted into the machine, the sections are arranged with one stationary section (fixed die half). At the same time, the other section can move (injector die half).
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These two halves are clamped together by the machine – thus, beginning the casting cycle.
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The die cavity is injected with a molten metal, which then rapidly solidifies.
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Once the die halves are pulled apart, the casting is ejected.
Die casting dies can be designed to be simple or complex, can possess moveable slides, cores, or other sections, depending on the casting’s complexity.
Is Die Casting Right for Your Product?
Die casting may not be the perfect solution for every project. One of the disadvantages of die casting is that it has a high mold cost. we offer a wide range of metal casting services, including:
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Lost wax casting
Some projects may also benefit from metal stamping or forging instead of die casting. The choice depends on a variety of factors, including the size, mechanical properties, and geometry of the part.
High-pressure Die Casting & Gravity Casting
At The Federal Group, we also offer high-pressure die casting and gravity casting based on the requirements of the project or the properties of the components.
Gravity casting is typically used for heavy products and high-volume production runs. It relies on gravity to allow the melted metal to naturally flow into the mold cavity. Compared to sand casting, this process is better suited for projects that require thin walls or a smooth surface.
Along with gravity casting machines, we have several types of high-pressure die casting machines including 600-ton, 800-ton. These machines allow for fast turnaround, thanks to shorter casting cycles.
Die Casting Machines
We have a versatile line-up of high-pressure die casting equipment:
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600 Ton die casting machine
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800 Ton die casting machine
These machines have excellent process repeatability and are capable of very quickly making parts with thin walls. Ideal for automation, our high pressure machines have short casting cycles that will optimize your production capabilities and will produce parts that are beyond your expectations.
The requirements of your components will dictate which die casting machine is the best solution for you.
Die Casting Materials
Die casting usually uses non-ferrous alloy material because it has a high dimensional stability. The four most commonly used alloys for die casting are:
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Aluminum
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Magnesium alloys
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Zinc
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Copper
The choice of die castings materials is influenced by several factors such as density, melting point, strength, resistance to corrosion, and cost. The material influences the type of machine used too.
Die Casting Dies
Die casting dies, also known as molds or tooling, are critical components in the die casting process. These dies are typically made using several key steps and consist of various components. Here’s an overview of how die casting dies are made and their main components:
Die Block Preparation
A large, solid block of the chosen die material is prepared, and it is typically milled, drilled, and machined to create the basic die shape.
Cavity and Core Inserts
The die is divided into two die halves or components: the die cavity and the core. The die cavity is the negative shape of the part to be cast, while the core is the positive shape. These components are precisely machined and are often made separately to allow for easy maintenance and replacement.
Ejector Die System
The ejector die system is designed to remove the cast part from the die once it has solidified. It typically includes ejector pins, ejector plates, and a mechanism to push the part out of the die.
What Is the Difference Between the Hot Chamber and Cold Chamber Die Casting Process?
We employ two types of die casting machines. Depending on the material and timeframe, we may use a hot chamber machine or a cold chamber machine. Both the hot chamber process and cold chamber process each have their own unique characteristics.
Hot Chamber Die Casting Process
Hot chamber die casting relies on a piston to force the molten metal into the dies. The hot chamber machine has a built-in furnace to heat the metal. The hydraulic-powered piston then forces the metal into the die at a fast pace with a typical cycle lasting just about 15 minutes.
Hot chamber die casting provides an efficient solution for tin, zinc, and alloys with lower melting points.
Cold Chamber Die Casting Process
Cold chamber die casting include an extra step in the process. Instead of a built-in furnace, these cold chamber machines require a separate furnace to melt the metal.
The molten metal is transferred to the cold chamber machine using an injection cylinder. The cylinder extrudes the metal into the die using a piston. The additional step of transferring the molten metal increases the production cycle of cold chamber die casting.
The main advantage of cold chamber die casting is the ability to work with a wider range of metals. Metals with a high melting point require the use of a separate furnace, which is not an option with hot chamber systems.
Cold chamber die casting is best suited for working with materials like brass, steel, copper, nickel, iron, and occasionally aluminum.
What Is the Difference Between Sand Casting and Die Casting?
While die casting relies on high pressure to force the liquid metal into the mold, sand casting involves pouring molten metal into a sand mold.
The sand casting process includes a mixture of sand and clay pressed into boxes called flasks. The model part is placed in the mixture, creating a mold. The molten metal is poured into the mold to create the desired shape.
When the metal cools, the sand is blasted away. Our sand casting process produces high-quality parts with minimal porosity and defects compared to die casting. Sand castings are also suitable for a wider range of materials.
While we offer alloy die casting services, die castings do not work with all materials. Sand castings can be made from various ferrous metals and non-ferrous alloys. However, sand casting is a more exhaustive process.