Die Casting Mold
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Metal Die Casting

Metal die casting is the technique of pouring molten metal into a high precision mold. Metal die casting is to force molten metal under high pressure into a mold cavity. It is made from non-ferrous metals specifically zinc, copper, aluminum, magnesium, lead, pewter, and tin-based alloys.

Metal die casting has excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.004 inches for the first inch) and 0.02 mm for each additional centimeter (0.002 inches for each additional inch).

It has smooth cast surfaces and thinner walls compared to sand and permanent mold casting.

Aluminium Die Casting

Aluminum die casting is the most common alloy die casting in the mold industry. Aluminum dies casting alloys are lightweight and posses high dimensional stability for complex part geometries and thin walls.

It withstands good corrosion resistance and mechanical properties as well as high thermal and electrical conductivity.

Besides, low-density aluminum metals are essential to the die casting industry. The Aluminum Die Casting process retains a durable strength at very high temperatures, requiring the use of cold chamber machines. The molten metal is still contained in an open holding pot which is placed into a furnace, where it is melted to the necessary temperature.

Alloy Die Casting

Die casting molds are usually constructed from hardened steel and they are often the most expensive component in a die casting machine.

These molds can handle a range of different alloy families like zinc, magnesium, copper, tin, bronze, brass, lead and also aluminum.

However, die casting is generally most effective on metals with low fusing temperatures. For this reason, the common die casting alloys fall into a handful of categories based on their composition and material properties.

Die-cast aluminum alloys are often used in automobile parts and gears. They are generally stronger and lighter than most zinc-based materials, but tend to be more expensive to create.

Die Casting Products

As a fabrication process, die casting is famous for its capacity to manufacture parts with a high degree of uniformity, close design accuracy, and quality surface finishes.

In many cases, die casting can reduce the need for post-production machining, raising the efficiency of the process and shortening fabrication time.

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies.

Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter, and tin-based alloys. Die casting could use either a hot chamber or cold chamber machine, which depends on the type of metal being cast.

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1. What is the die casting?
Die casting involves the preparation of components by injection molten metal at high pressures into a metallic die.

2. What is the process of die casting?
The casting cycle starts when the two parts of the die are apart. The lubricant is sprayed on the die cavity manually or by the auto lubrication system. The two die halves are closed and clamped. The required amount of metal is injected into the die. After the casting is solidified under pressure the die is opened and the casting is ejected.

3. Two types of die casting machines?
Hot chamber die casting
hot chamber die casting

Cold chamber die casting
cold chamber die casting

4. Types of dies
Die casting molds are often divided by the alloy they handle like zinc, magnesium, copper, tin, bronze, brass, lead and also aluminum. For example, die casting mold which handles aluminum can be called aluminum die casting.

5. What are your minimum annual order quantities?
Normally we would quote MOQ 1000 per order. The more you order, the cheaper the price would be.

6. Do you offer prototyping services?
Yes, Five-Star could offer prototyping services.

7. If I send you a 3d cad (step) file, why do you need 2d drawings?
2d drawings have requirements on tolerances, part materials, etc., which is very essential for getting a precise quotation or kicking off projects.

8. What other question can I answer to receive a quick turn around on my quote?
Five-Star needs 2d printings and 3d models to provide a quotation. Besides, if you have requirements on cavities, hot runner, cold runner, delivery time or any other needs, please make sure to pass the information when you’re sending us an inquiry. A tool specification would be even better. We would according to your specific needs to offer you a quotation ASAP.

9. Can you sign our NDA before we provide sensitive project information?
Yes, Five-Star has experienced signing NDA with our customers and we always strictly follow the instructions to protect our customers’ privacy.

10. Does Five-Star guarantee die life?
Yes, Five-Star would provide guarantee die life on our quotations.

11. What materials does Five-Star offer?
We only use raw materials with good quality like P20, P20H, 718H, NAK80,1.2311,1.2378, 1.2344,1.2343 ESR, 1.2767, H13,8407, 420SS, S136, S-7,etc. They are all from famous suppliers, such as LKM, ASSAB, THYSSEN, etc.

12. What are the advantages of die-cast components?
Metal die casting has excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.004 inches for the first inch) and 0.02 mm for each additional centimeter (0.002 inches for each additional inch). It has smooth cast surfaces and thinner walls compared to sand and permanent mold casting. Besides, it is the fastest technique available for producing precise non-ferrous metal parts.

13. What are the advantages and disadvantages of die casting?
Advantages of die casting:
1. Excellent dimensional accuracy.
2. Smooth cast surfaces.
3. Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75mm or 0.030 in)
4. Reduces or eliminates secondary machining operations.
5. Rapid production rates.
6. Casting tensile strength as high as 415 MPa.

Disadvantages of die casting:
1. Casting weight must be between 30 grams and 10 kg.
2. Casting must be smaller than 600 mm
3. High initial cost.
4. Limited to high-fluidity metals.
5. A certain amount of porosity is common.
6. Thickest section should be less than 13 mm
7. A large production volume is needed to make this an economical alternative to other processes.

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