Die Casting Using Magnesium – The Best Casting Option

Die casting is a process by which molten metal is forced to take the shape of the mould it is poured into by using high pressure. During the process of casting, the hardened die acts like a metal injection mould. Various metals are used in the process of casting. Most castings are made from metals that are non-ferrous in nature as they are durable and strong. The list of die cast metal includes zinc, copper, aluminium, magnesium, lead, tin and so on. Magnesium die casting is the most popular and widely for die casting.

The use of magnesium has gained a lot of popularity because of the characteristic features of the metal. Magnesium is one of the easiest metals to carry out the process of die casting because of its inherent properties. Plus, it has a lower melting point when compared to the other die casting metals. So, the casting process takes lesser time for completion, which will allow manufacturers to increase their daily production count.

Even though this metal is lightweight, it has immense strength. Its lightness makes it the prime reason for use in many production processes. Magnesium is also less expensive when compared to other thermoplastic materials. This metal can also be used to create products with thin walls as it retains its strength even when its thickness is less. It is a corrosion resistant metal, which is not affected by environmental factors like air, water and moisture. Magnesium is also recyclable, which means more savings in the long run. Plus, you don’t have to deal with waste management. It helps save money by reducing the need to procure new metal every time, and on the other hand, it recyclable nature makes it an environmentally friendly raw material. All these factors make magnesium a good choice for die casting.

While creating the metal injection mould for magnesium die casting, you can add in all the minute details in the cast design. Based on the product, you can decide where to set the parting line, about the number and placement of the ribs and other features. If you want you can also add your company logo and manufacturing particulars while creating the cast design. So, the final product will come complete with all the details embedded, and all you have to do is give it a final finishing touch and send it down the delivery line.

Reduce Manufacturing Costs with the Right Die Casting Design

In the die casting process, molten metal is poured into a mould that is designed in the shape of end product. The molten metal is injected at very high pressure into the mould, so it takes up the shape of the mould. This die casting process is efficient and economical as it saves time, effort and also decreases wastage at the same time. Different metals such as zinc, tin, magnesium and aluminium as well as their alloys are used in the die casting process.

There are small steps that you can take to further reduce aluminium die casting process expenses. The entire production process can be made less costly by making subtle changes in the die casting design.

Reduce the Weight

When you reduce the volume of components required for die casting, you can proportionately decrease the weight and cost of die casting. If you pour more metal into the cast, then it will take more time to set and cool, which will eat up into your production time. So, you can go for slight alterations in the die casting design like designing pockets to make thinner cross sections or use ribs to strengthen the cast product. Care should be taken while designing the location of the pockets because the wrong positioning of the pockets can affect the product’s accuracy and strength.

Parting Lines and Ejector Pins

While designing the aluminium die castings, careful consideration should be given to the parting lines and ejector pins. The parting line should preferably be straight or flat, so removal becomes easy. Ejector pins are used to remove the cast products from the mould. If the pins are neatly designed, then they will not leave any marks on the cast when it is removed from the mould. So, you finished product will not have any unnecessary marks and scratches which could then require another finishing touch.

Radii and Fillets

While creating the Die Casting Design, care should be taken to avoid sharp corners. If there are less sharp corners in the Aluminium Die Castings, the finished product will be stronger and have a cleaner finish. Also, there should not be quick ups and downs in the cross section, which will lead to erratic flow of molten metal in the cast, and finally lead to an irregular finish.

There are lots of the other techniques that can be used while designing the cast. These techniques will not only ensure product strength, but also reduce production time and decrease manufacturing costs.

Aluminium Die Castings – An Economical Method for Metal Manufacturing

In the recent decades, there has been unprecedented improvement in various manufacturing fields, thanks to the development of the die casting technique. This method has made it easy for manufacturers to mass produce metal parts without any loss in quality or extra use of labour. The die casting is a pretty simple technique that involves melting compatible metals and pouring the molten metal into a mould. The cast or the mould is designed in the shape of the product for production. After the metal solidifies, the cast is broken and the metal part is removed. This metal manufacturing process has been adapted by various companies for manufacturing electrical equipment, automobile spare parts and other metal alloy-based products.

Any industry will adapt to a process only if it has any advantages for them. Aluminium die casting techniques have made the manufacturing process more efficient and economical. A huge benefit of using the die casting method for metal manufacturing is that one can produce thin-walled products without loss of strength or integrity. The cast can be designed in such a way that tiny additions are made to the casting, so it retains its strength even if the walls are thin. This process allows manufacturers to produce small parts without much hassle.

Aluminium die castings have high strength as well as a good finish, so manufacturers don’t have to spend extra time, effort and money on polishing the final product before sending it to the market. Plus, this technique allows manufacturers to produce very high volumes of products without using much manual labour. From melting the metal alloy to pouring it into the mould, most of the process can be automated.

The casts can be cut into complex shapes, and all the ribs, marks and other details can be engraved on to the inside of the cast. So, when the metal solidifies, all the markings and carvings are automatically embedded on the finished cast. You don’t have to spend extra manual labour in making those final finishing touches to the manufactured process. Plus, the scrap generated by this metal manufacturing can be recycled and used in the next manufacturing cycle. So, by using this method, you can greatly reduce wastage of metal.

As with all technologies, aluminium die casting too comes with certain disadvantages. You will have to invest more in the beginning for the cast and the tool. Plus, the lead time is a little long. Overall, if you consider all the pros and cons, we can safely say that this metal manufacturing process is indeed economical.

An insight into Precision Aluminium Die Casting

Casting is a manufacturing process by which a liquid material is usually poured into a mould, which contains a hollow cavity of the desired shape. The liquid metal is then allowed to solidify, so that it takes up the shape of the mould when it comes completely solid. The solidified part is known as a casting, which is ejected or broken out of the mould to complete the process.

Precision die casting has been used since in the ancient period, to make jewellery and other small products. In the recent years, however, this manufacturing technique is used for manufacture of automobile spare parts and electronic items. The best part of using aluminium die casting for manufacturing spare parts is that you can produce even the smallest of parts with the utmost precision. This manufacturing technique allows manufacturers to embed minute details into the cast design, which is reflected in the final product. Like for example, the logo of the company can be embedded in the cast design. When the molten metal solidifies, the logo is marked on the cast. So, the manufacturers don’t have to spend extra time and effort to add the company logo to the finished product. If all the details are meticulously noted when the cast is designed, then the manufacturer will be able save money on the entire production process.

Aluminium alloys are popularly used in most die casting techniques as it is easy to cast and offers durable results. Plus, aluminium is a non ferrous metal. The adoption of Aluminium die casting method comes with a bundle of benefits. Aluminium metal is a very light weight metal to cast, and it offers high dimensional stability for complex shapes and thin walls. It has good mechanical properties such as high thermal and electrical conductivity. Above all, it retains strength at high temperatures and it is also corrosion resistant.

Precision casting techniques have made manufacturing processes much easier than before. They are now widely used in a lot of manufacturing industries for faster and better production of products. Die casting technique is preferred by most manufacturers as it reduces metal wastage, which again adds to their profit levels. Scores of other alloys of zinc, lead, tin and other metals are also used in die casting. This versatile manufacturing technique has brought about a sea change in the production line of a number of components and spare parts. 

Why Should You Choose the Best Metal Components Manufacturers?

Metal manufacturing is quite a complex process. Various processes are used for manufacturing metal amongst which casting is a commonly used process. Here, molten metal is poured into a mould cavity and the metal solidifies and takes the shape of the cavity. So, you have your metal ready in the desired shape. Depending on the kind of mould used, casting is divided into three types: expendable mould casting, permanent mould casting, and powder metallurgy. The process and technique vary for the different types. Deformation is another process used for manufacturing. Here, a tool is used to apply stress to the metal, which eventually yields to the stress of the metal and gets deformed. In the material removal process, extra material is removed from the work piece. This is done to eventually achieve whatever shape is desired.

After metal manufacturing, you need to put the metal into good use and it needs to be fabricated. It needs a series of separate processes to be done in a chain like manner, one following the other. Cutting process, bending process, and assembling process are the 3 main operations that take place in the fabrication of metals. These processes are performed to build metal structures. These metals are then used for various purposes. In every kind of manufacturing or construction industry, these metals play an important role. In the automobile industry, all kinds of spare parts and tools are made using fabricated metals. The list of uses is just endless. Every place you look, you will find some use or the other for fabricated metals.

Sawing, chiseling, or shearing is generally used for the cutting process. They can be either fully automated or manual. You have automatic cutters and machines for this purpose. After cutting comes the bending process. Press brakes, hammers, or other such tools are put into use for this process. Now you even have software that can program the bending process and increase the efficiency multifold. Assembling involves riveting, welding, adhesives, or other such techniques to put together and join the pieces. This can also be manual or automated. After the assembling process, your fabrication is ready. Metal components manufacturers perform all these steps to manufacture the different components that you use in your day to day lives.

There are a number of metalcomponents manufacturers available, who claim to offer you the best services. Whenever you approach a manufacturer, you must be careful and consider a few things such as the purity of the metal and the efficiency of their work. To ensure good quality products, you need to approach only the best. With Dynacast, all your requirements are thoroughly studied to offer you the best product as per your preferences.