Faqs

The die casting process is highly productive and suitable for mass production. Once the mold is made, a large number of parts can be produced efficiently. Due to the high pressure injection of molten metal to fill the mold, the parts can be formed in a short period of time, shortening the production cycle, especially suitable for industries with high demand, such as the automotive and electronics industries.

The following defects may occur during the die casting process:

• stoma: A cavity formed when gas fails to escape or cools unevenly.
• cold storage: A crack or weak area formed by the failure of the metal to flow and join completely.
• crackles: Cracks caused by improper mold design, uneven cooling or excessive metal stress.
• surface defect: such as scratches, bubbles, etc., which may affect the cosmetic quality of the part.

Yes, die castings usually require some post-processing to further improve dimensional accuracy and surface quality. Common post-processing techniques include:

• machining: Such as milling, turning, etc., for resizing parts and removing burrs or irregular surfaces.
• surface treatment: Such as sandblasting, polishing, anodizing, etc., used to improve the appearance quality and corrosion resistance of parts.
• hot treatment (e.g. of metal): To improve the hardness and strength of a part by annealing, quenching, etc., to meet specific work requirements.

Tolerances for die casting processes are usually between ±0.1mm and ±0.5mm, with the exact tolerance range depending on the size and shape of the part. Through precise mold design and strict process control, die castings can achieve high dimensional accuracy and are suitable for industrial applications that require high tolerance requirements.

The lead time for die casting molds is usually 4 to 8 weeks, depending on the complexity of the mold, the choice of material, and the production capacity of the manufacturer. If the mold design is complex or requires multiple adjustments, the lead time may be extended.

Porosity is formed when gas or air is not completely expelled from the molten metal. Common causes include poor exhaust design, excessive metal injection rate, and uneven cooling. Measures to avoid porosity are:

• Improved exhaust design: Ensure that the mold is designed with adequate air vents.
• Control of injection rate: Avoid excessive injection pressures and velocities that result in trapped gas.
• Optimization of casting temperature: Ensure that the molten metal is at the right temperature and avoid overcooling or overheating.

The following points need to be considered for die casting design:

• Wall thickness uniformity: The wall thickness of the part should be uniform to avoid cold segregation or distortion.
• Rational exhaust design: Design venting holes to expel air and gas to avoid porosity defects.
• Cooling system design: There should be suitable cooling channels inside the mold to ensure uniform cooling of the molten metal and to reduce internal stress and deformation.
• Runner and gate design: Reasonable design of runner and gate system to ensure the smooth flow of metal into the mold to avoid defects.

Die casting is a casting process in which molten metal (e.g. aluminum, zinc, magnesium alloys) is injected into a precision mold under high pressure. The process is capable of producing parts with complex shapes and precise dimensions, and is widely used in the automotive, electronics, and home appliance industries. Through high-pressure injection, the molten metal fills the mold, and after cooling, the part is formed with good surface quality and high strength.