Lamps And Lanterns-Description Of The Die Casting Process
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    • Last updated August 11, 2020
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Lamps And Lanterns-Description Of The Die Casting Process

Posted By anna xinxinmetal     August 11, 2020    

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The traditional die casting process is mainly composed of four steps, or called high pressure die casting. These four steps include mold preparation, filling, injection, and shakeout, which are also the basis of various improved die casting processes. During the preparation process, a lubricant needs to be sprayed into the mold cavity. In addition to helping to control the temperature of the mold, the lubricant can also help demold the casting. Then you can close the mold and inject the molten metal into the mold with high pressure. The pressure range is about 10 to 175 MPa. When the molten metal is filled, the pressure will be maintained until the casting solidifies. Then the push rod will push out all the castings. Since there may be multiple cavities in a mold, multiple castings may be produced during each casting process. The process of falling sand requires the separation of residues, including mold openings, runners, gates and flash. This process is usually done by extruding the casting with a special trimming die. Other methods of falling sand include sawing and sanding. If the gate is fragile, the casting can be directly beaten, which can save manpower. The excess mold opening can be reused after melting. The usual yield is about 67%.

High pressure injection results in a very fast filling of the mold so that the molten metal can fill the entire mold before any part solidifies. In this way, even thin-walled parts that are difficult to fill can avoid surface discontinuities. However, this can also lead to air entrapment because it is difficult for air to escape when filling the mold quickly. This problem can be reduced by placing an exhaust port on the parting line, but even a very precise process will leave pores in the center of the casting. Most die-casting can be completed by secondary processing to complete some structures that cannot be completed by casting, such as drilling and polishing.

Defects can be checked after the sand has been shaken out. Common defects include stagnation (unsatisfactory pouring) and cold scars. These defects may be caused by insufficient mold or molten metal temperature, metal mixed with impurities, too few vents, and too much lubricant. Other defects include porosity, shrinkage, thermal cracking, and flow marks. Flow marks are traces left on the surface of castings caused by gate defects, sharp corners or excessive lubricant.

Water-based lubricants are called emulsions, and they are the most commonly used type of lubricant for reasons of health, environment and safety. Unlike solvent-based lubricants, if the minerals in the water are removed by a proper process, it will not leave by-products in the casting. If the water treatment process is improper, the minerals in the water can cause surface defects and discontinuities in the castings. There are four main types of water-based lubricants: water mixed with oil, oil mixed with water, semi-synthetic and synthetic. Lubricants mixed with water are the best, because when using lubricants, water deposits oil while cooling the surface of the mold through evaporation, which can help demold. Usually, the ratio of this type of lubricant is 30 parts of water mixed with 1 part of oil. In extreme cases, this ratio can reach 100:1.

Oils that can be used for lubricants include heavy oils, animal fats, vegetable fats, and synthetic fats. Heavy residual oil is highly viscous at room temperature, but at high temperatures in the die-casting process, it becomes a thin film. Adding other substances to the lubricant can control the viscosity and thermal properties of the emulsion. These substances include graphite, aluminum, and mica. Other chemical additives can avoid dust and oxidation. Emulsifiers can be added to water-based lubricants so that oil-based lubricants can be added to water, including soap, alcohol, and ethylene oxide.

For a long time, commonly used solvent-based lubricants include diesel and gasoline. They are conducive to casting out, but each time a small explosion occurs during the die casting process, which causes the accumulation of carbon on the cavity wall. Compared to water-based lubricants, solvent-based lubricants are more uniform.


Jiaxing Yunhe Trading Co., Ltd. specializes in producing aluminum alloy die-casting, zinc alloy die-casting and other non-ferrous metal die-casting products. Our products mainly cover automobiles, motorcycles, auto parts, luggage, medical equipment (wheelchairs),   Lamps and lanterns   , LEDs, locks, connectors, elbows, strollers, belt buckles, hardware accessories. Welcome to view product details: https://www.xinxinmetal.com/

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