Die Casting Process - History and Advantages

Aluminium die casting came into being in the 18^th Century. It was originally created to produce movable parts for the printing industry. An automated type casting device called the Linotype machine was created by a man named Otto Mergenthaler in 1885. This became popular equipment used in the printing and publishing industry. Die casting led to the creation of other designs and applications used to create products of different kinds to ease the growth and demand of consumer goods. This gave way to the mass production of aluminium goods. The year 1892 saw the mass production of phonographs and cash registers. These parts were mainly made out of tin and lead. 

 

Developments and newer applications gave way to using metals like aluminium, zinc, magnesium and copper. Today, one can find a number of aluminium die casting companies the die casting process can be used to accommodate products of various shapes and sizes. 

 

Aluminium die casting are made by injecting molten metal with considerable force into a steel mould called a die. The sizes of the die casting machines can be anywhere between 400 and 4000 tonnes. There are two methods used to inject the molten metal. The methods are the hot and cold chambers. Hot chamber machines are also known as goosenecks. A pool of molten metal is used fill the gooseneck and then the metal is injected into the die using a hydraulic piston. 

 

Cold Chambers are used when it comes to die casting metals like aluminium, magnesium, zinc and copper. Then a certain amount of molten metal is poured into a cold chamber and is injected into the die. This process is slower than the hot chamber process.

There are reasons why aluminium is preferred than other metals when it comes to the process of die casting.

• It is lightweight, and at the same time has the appropriate amount of weight and stability
• It has good resistance against corrosion
• It has thermal and electrical conductivity
• It can maintain its strength even at high temperatures

There are many reasons why aluminium die casting products and companies are popular.

Fast production: Die casting provides complex shapes with dimensional accuracy and stability. Little or no machining is required to create dozens of identical castings. The products are durable, resistant to heat and long lasting.

Strength and weight: Plastic moulded products do not have the same weight and strength that die cast parts do. Thin wall castings made from aluminium are stronger and lighter than those possible with other casting methods. 

 

Easy Surface preparation: Die cast parts are plated quite easily and they require minimum surface preparation. They can also be produced with smooth or textured surfaces.

Aluminium die casting companies have to follow strict quality control procedures to make sure their products reach popular standards of excellence. Thanks to these reasons, companies can make more than 500 million in producing and selling aluminium products.

Aluminium Die Casting Process

Die casting is a process where molten metal is put into a mould cavity using considerable pressure. The die casting method is a low cost and high product generating method. It is mainly used for producing small or medium sized parts. 

 

Die casting is used in a variety of industries including the industrial, consumer and commercial industries, which require using different kinds of metals for different products. Die castings are usually made of metal alloys like zinc, copper, aluminium, tin and lead. Companies that specialize in die casted parts use various methods to manufacture the components. 

 

The major ones are gravity die casting, high pressure aluminium casting and low pressure aluminium casting. Alloy wheels are made using the low pressure aluminium casting process. Aluminium die casting is one of the more popular methods. 

 

Aluminium is a popular metal alloy used. The reason behind this is that aluminium is a light weight metal, but also has an ability to remain stable when moulding it into complex shapes. It retains its strength at high temperatures. It has a very good resistance to corrosion. Aluminium is known its good mechanical properties and its high electrical conductivity. 

 

The automotive industry is one of the biggest industries to use parts that have been manufactured using the aluminium die casting process. Many automotive companies have replaced steel with aluminium for the car’s frame and automotive components. The reason for this is that aluminium is lighter than steel, making the car leaner and faster. Lighter cars mean less consumption of fuel. It is easier to mould it into complex parts. Also, the labour cost for aluminium is less. 

 

With a high demand for aluminium parts, many aluminium companies have come up that cater to the industries, manufacturing aluminium die casted parts. The die casting process also allows the manufacturers to produce the product according to the client’s specifications. The products can be light weight, ranging from a few 100 gms to a few kgs, depending on the requirement.

One of the newer processes that have been introduced in die casting is the pressure injection process. A number of methods are being used to automate the die casting process. This helps to continuously provide quality control. Automated systems are used to ladle metal into chambers, lubricate dies. Microprocessors adjust pressure and velocity to create the product according to the specification provided. Thus, it is simple to produce a component of according to one’s needs.

 

The work of aluminiumdie casting manufacturers is majorly influenced by the research and development that goes into creating better systems to improve the production process. R&D usually comprises a highly qualified team that handles a large amount of imported and indigenous equipment. Automotive components manufacturers use the aluminium die casting process so that the component will have a long life. They can be designed to add to the visual appeal of the vehicle. That is why many automotive designers ask for parts that can be produced using the aluminium die casting method. 

Learn More-  Alloy wheel manufacturer

Advantages And Importance Of Alloy Wheel

This blog discusses alloy wheels, how it has become a popular option for wheel manufacturers and a favourite of customers. It has also become a must have customers from different vehicle genres.

The alloy wheel, once considered a poor option for motorsports, has become a world favourite for anyone who loves anything to do with motor vehicles. During the 1960s and 70, alloy wheels or ‘mags’ (derived from the fact that they were made from aluminium and magnesium) were not considered safe for common vehicles. This was due to the fact that aluminium, though light in weight is brittle, and technology hadn’t improved to give it strength as well as keeping it lightweight.

As technology and motorsports began to grow in size and popularity, new ways to produce aluminium were developed, making the metal stronger and at the same time maintaining its weight. Most alloy wheels are cast and few brands are forged. The ability to mould the metal and creating beautiful designs for tyres has made the wheels an important component for luxury or sport vehicles. Many companies even offer alloy wheels exclusively for some of their products.

Today, aluminium is a hot favourite for people who manufacture motor vehicles and motorsports enthusiasts. Many feel that having a larger alloy wheel is better not only for the bike but also for the atmosphere. But test by various auto magazines have indicated that having large alloy wheels reduce the fuel economy of a vehicle. It also affects the riding comfort and noise from the tyres. 

Many companies that produce super cars and sport cars are known for their love of alloy wheels. This is a trend that is seen in many countries around the world, including America, Italy, Britain, and of course, Germany. 

But that hasn’t removed the allure of the wheels from the eyes of customers. It is still considered a favourite by enthusiasts. And India is certainly no different. One of the main cities where motor vehicles are manufactured in India is Pune. The city, which in recent years has been dubbed ‘Detroit of India’, has become a haven for auto manufacturing companies. Many alloy wheel manufacturers and distributors have also come up here. Wheels other products are cast using intricately shaped castings and they weigh between 400 gms to 8.5 kgs per piece. Manufacturers make sure to do most the work in-house, from high pressure; low pressure and gravity die casting, to machining, painting and finally assembly. Only a few products like Clutch Housing, Converter Chamber, Cylinder Head Cover, Front Wheel Hubs are sent for overseas casting.

Learn More - Aluminium Die Casting Manufacturer