Die Casting Service
The DAHE Advantages
Comprehensive Equipment
Our die-casting facility is anchored by a powerful 2500-ton cold chamber die-casting machine, capable of producing large, high-integrity components up to 800x800mm, perfect for demanding industrial applications.
Established Expertise
Leverage over 36 years of mechanical processing experience, specifically honed in advanced techniques like die casting, to ensure your complex components are manufactured with precision, durability, and a deep understanding of material science.
Proprietary ERP System
From initial design to final delivery, our proprietary ERP system ensures meticulous management and barcode tracking of every die-casting step, guaranteeing product quality and strict adherence to delivery schedules for your critical components.
Die Casting
Die casting is a metal casting process that forces molten metal under high pressure into a mold cavity, creating precise and complex metal parts. The mold, often made of hardened steel dies, is designed to create the desired shape, and the molten metal is injected at high speed and pressure. This method is particularly suitable for mass production of non-ferrous metal components with smooth surfaces and tight dimensional tolerances.
Die Casting Process
1. Die Preparation
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The die, made of hardened steel, is prepared by cleaning, lubricating, and sometimes heating it to ensure proper metal flow and easy part removal.
2. Metal Melting
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The chosen metal alloy is melted in a separate furnace to a precise temperature.
3. Injection
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Hot Chamber: In hot chamber die casting, the molten metal is directly siphoned from the furnace into the die. This method is typically used for metals with low melting points, like zinc.
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Cold Chamber: In cold chamber die casting, the molten metal is ladled from the furnace into a cold chamber and then injected into the die. This method is suitable for metals with higher melting points, such as aluminum.
4. Cooling and Solidification
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The molten metal is injected into the die cavity under high pressure, filling the mold and taking its shape.
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The metal then cools and solidifies within the die.
5. Ejection
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The die is opened, and the solidified part is ejected using pins or other mechanisms.
6. Trimming
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Excess material (flash) and runners are removed from the part.
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Post-machining
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Some casting parts require precision machining for holes, threads, and other features.
Material
Cross Reference of Alloys from Different Standards
REFERENCE Alloy | JIS (Japan) | AA (USA) | ASTM | CSA | DIN (Germany) | NF | BS (UK) |
|---|---|---|---|---|---|---|---|
Al-Si | AC4C | A356 | SG70N | LM25 | |||
Al-Si | AC3A | A413.2 | S12A.B | G-ALSi12 | A-S12 | LM6 | |
Al-Si | ADC1 | A413 | S12A.C | GD-ALSi12 | A-S13 | LM20 | |
Al-Si-Mg | ADC3 | A360.2 | SG100A | GD-ALSi10Mg | LM20 | ||
Al-Si-Cu | ADC10 | A380.1 | SC84A | SC84P | GD-ALSi8Cu3Fe | A-S10U4 | LM24 |
Al-Si-Cu | ADC12 | A383 | LM2 | ||||
ADC14 | B390. | LM30 | |||||
Al-Mg | ADC5 | A518.2 | G8A | G8 | GD-ALMg8Cu | A-G6(11) | |
Al-Mg | ADC6 | A514 | G4A | GS40 | GD-ALMg3Cu | A-G3T | LM5 |
A199.5 | 1050 | 995 | A5 | 1B | |||
ER5052 | 5052 | AlMg2 | 2L.55 | ||||
6061 | |||||||
7075 |
Common Die Casting Applications
Die casting is a powerful, versatile process suitable for a range of parts, from engine components to electronics housings. Reasons for the versatility of die casting include its large build area, range of material options, and ability to make detailed, repeatable, thin-walled parts.
Automotive
Aluminum die casting is popular in the automotive industry as it can produce lightweight components like hydraulic cylinders, engine brackets, and gearbox cases. Zinc die casting is suitable for fuel, brake, and power steering components, while magnesium die casting works for panels and seat frames.
Aerospace
As in the automotive industry, aerospace parts suppliers use aluminum die casting to make lightweight parts that exhibit a high level of heat and corrosion resistance. Lightweight parts reduce fuel usage.
Energy
Die casting parts in the oil and gas sector include valves, filtration components, and impellers. Renewable energy parts can also be die cast.
Electronics
Die casting is prevalent in electronics, as it is used for items like enclosures, housings, and connectors. Die casting parts can also be designed with incorporated heat sinks, which are necessary for many devices. Magnesium die casting is popular for thin-walled RFI EMI shielding components, while aluminum die casting for LED light components is widespread.
Construction
The construction industry uses aluminum die casting for large structures like building frames and window frames.
Engineering
Lifting equipment, machine tools, and other equipment often contain die cast components.
Medical
In healthcare, die casting can be used for monitoring device components, ultrasound systems, and other items.