The Die Casting Process

Basic Aluminum Casting Co.

For over half a century The Basic Aluminum Casting Company has been a privately held, financially solid die casting company with a professional integrity matched by few in today’s industry.diecasting

At The Basic Aluminum Casting Company, we bring quality die casting with delivery and pricing achieved through a sound business organization. Centrally located in Cleveland, Ohio, we’re easily accessible across the Midwest and the entire United States. Occupying over 55,000 square feet at our plant, Basic has serves the transportation and general manufacturing industries and beyond! The Basic Aluminum Casting Company can be best described as an engineering company with one simple trait – creating die cast products  from listening and understanding our customer’s needs.  A strong commitment to that and a focus on quality has enabled us to continue to be one of the best and oldest names in the industry.

Ever wondered how metal toy soldiers were made or how some items turn up to be shaped as they are? Manufacturers don’t mold these shapes like they do for clay pots, instead, the usual process is through die casting.

Die casting manufacturers can choose to die cast their alloys through any process most appropriate for the finished product. One of the processes used is by having the metals die cast in high pressure. This is the most common way to die cast many other metal alloys, representing about 50% of all production. The low pressure die cast method, on the other hand is used only about 20% of the time for only special products, yet its usefulness increases within time. Other die cast methods are gravity die casting – which amounts to the remaining percentage of production with only a little less left for recently introduced processes – squeeze die casting and vacuum die casting.

Aluminum is a lightweight alloy that has high stability for different shapes and even thin walls while also having good resistance and mechanical properties. With aluminum’s strength in high temperatures and the ability of conductivity in both thermal and electrical, it has a lot of usage for manufacturers of high end products. Each metal alloys has their own special way of die casting and this does not go a different way with aluminum. In die casting aluminum, the mold is not always destroyed or used only for the purpose of creating a figure closer to the finished product itself. Other die casting manufacturers who use aluminum parts keep the mold permanent as it would provide an outer protection for the aluminum itself. Die casting manufacturers use the cold chamber process for aluminum because of their high melting points.

It is important to choose a trusted die casting manufacturer who knows the best way to customize production process for the advantage of the part or product they intend to make.

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Die Casting Advantages
Die Castings can be used for a lot of things. In production, companies use the die casting method to mold and produce products that will eventually be designed and sold to the markets. These products include toys, decorative and sometimes, even statues. Others are just molded to make up another part of a product like those for cars and appliances or to aid an even bigger product to be produced at a later date.

 

Die castings have incredibly strong features, making it one of the best ways to produce metal products. To create die castings, molten metal is laid into mold cavities (to which the size varies by the size of the product and the allowance required by the designer or architect) by high pressure and the metal hardens to the shape of the cavity. This process can be done in two ways – the hot chamber or the cold chamber process.

As one of the most useful ways to create products, companies have to compute its value to their production process. Die castings have a lot of advantages compared to other more complicated forms of shaping and creating metal forms.

One of these advantages is that the dies used for die castings can be used repeatedly. This means that the company can save up on money in having to purchase metal only to be wasted after cut off or removed by the designer throughout the shaping process. Any metal used in die castings but not included in the finished products may be reused for a second die cast project. Not only that, the process of die casting is automated, thus there is less risk of waste, man-errors and less time wasted as each process is done at a certain amount of time by the machines used for die castings.

When die casting metal, post machine processes can be avoided as the whole method of shaping up metal can be relied on to the after-process or the designer who will be shaping up the finished product. The die casting method is also quite useful to companies because its process can be applied to a wide range of metals that can be molded and utilized for several other products. Since metal is the main variable in creating die casts, most products undergoing die casting are considered to be strong, bearing long service lives, easy access to building products with accurate measurements and all the other advantageous features metal can bring to a product.

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The Importance of Finding the Right Manufacturer
For a business looking to spread its wings, finding the right partners to trust is very important. Decisions are the necessary steps to a company’s successful growth and only the right decisions will lead the company to a fruitful future. In the die casting industry, the right die casting manufacturer is the key to the best products, increase of profits and income as well as development of the company. However, if the company doesn’t work with the right manufacturer, the consequences are high and the aftermath of wrong decisions will hurt the company’s growth process.

It is necessary to find the right die casting manufacturer because only the right production people will help the company in saving money. The die casting process is quite expensive and usually only a volume production can save a company on such large costs of manufacturing. With the right manufacturer, the company may be able to negotiate plans, rework costs and agree to the right metals and alloys that will work best with the desired product. Only the right manufacturer will work with as little human and mechanical errors as possible to avoid any further cost coming from your company.

The best die casting manufacturer has a way of overseeing what’s best for a company and their production requirements. They know what’s right, what materials to use and will automatically think of the excess details that the company will want for their products. These manufacturers have a way of tailoring services, especially for their customers and knowing what will make the customers happy and not burn their pockets as much. They will provide a comparative list of competitive prices, packages and details that will help the company to see the choices they have and compare for the benefit of their production processes.

Experienced die casting manufacturers understand the importance of time and how a product’s success may have to depend highly on the time released and availability of it in the market. They know how much time they have and will not waste on any cost, even if there are inevitable events or accidents that may happen throughout the process, a good manufacturer will have a back-up plan to keep the production process going at the right pace without compromising the quality of the product and finished item. The right manufacturer for your company will vary by experience, price and packages, time and the competitive die cast processes they can provide.

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DieCastings – More Familiar Than You Think
Have you ever tried staring at your laptop long enough to appreciate the fine details on its metal casing? No? Well I guess by now you would have looked. In case you are wondering how those details are done, the most popular answer is diecastings which refers to a process by which molten metals are placed into steel molds to produce engineered metal products. These engineered metal products are actually everywhere.

Think: computer metal casings, car engine, heat sinks, that toy train, the treadmill, your faucet.

The process is widely used today because of the high demand for metal products that require intricate details to function. Using different sorts of shapes, sizes as well as thickness, castings are produced in undeniably durable and precise modes.

The diecastings process, technically, happens by injecting molten metal under high pressure into metal molds called dies. There are two methods of die casting, these are hot chamber and cold chamber. The two methods differ only by the process of injecting the molten metal into a die. The hot chamber method is used for low melting point alloys. The molten metal is injected through a goose neck from a furnace. A plunger forces the molten metal into the mold and forces the molten metal to take the shape of the mold. The cold chamber, on the other hand is used for alloys with high melting points. The molten metal is poured into a “cold chamber” by a ladle and a plunger seals the cold chamber port and oblige the molten metal to take the shape of the mold using high pressure.

Imagine the waffle maker, think of the waffle mix as the molten metal and the waffle maker, with all that crisscross details, as the die casting machine. The waffle maker uses the cold chamber method as the waffle mix is poured into the chamber using a ladle. That is basically the same molding process except that in die casting, details are more intricate and precise.

The process has definitely plenty of advantages. The very obvious is the dimensional accuracy and stability of its products. Die casting machines can produce very precise details with very little machining or process required. These machines can produce by bulk with long service life (very economical for mass production). Another advantage is the broad range of shapes and designs with accompanying durability. Now look at your laptop, or your computer, or your phone, that tiny hole above your screen just enough for the web camera to peek at, now you know it is not carved manually by someone. It is a product of precision from the diecastings process.

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Die Castings – More than Just Metals
The processes involved in die castings are definitely complex ones that necessitate expertise and experience. A die is defined as a material shaping device, while casting is defined as a manufacturing process by which a mold, which contains a hollow cavity of the desired shape, is filled with a molten metal and allowed to solidify.

Joining the two words together, die casting is defined as a manufacturing process by which a desired shape of a metal is obtained by using a mold (die).

When it comes to die castings, there are two specific types involved: the hot chamber die casting and the cold chamber die casting.

Both processes are accomplished by delivering a molten metal into a die cavity to produce the desired shape. The difference lies only on the method of preparing the injection system. The injection system is the part of the machine that carries the molten metal into the mold.

In the hot chamber process (also tagged as the gooseneck process), the cylinder chamber of the injection or the gooseneck mechanism is completely immersed in molten metal bath. As the name suggests, a hot furnace holds the molten bath, which is then processed to be injected into the injection mechanism. This allows the molten metal to be drawn right into the injection pump and right into the die cavity. This process is convenient and quick, but has increased corrosion susceptibility. This process is best suited for metals with low melting points and high fluidity. Examples of metals with low melting points and high fluidity include lead, magnesium, zinc and copper.

The cold chamber process, on the other hand, is used with high melting point alloys. Aluminum is an example of a high melting point alloy. Molten metal, which is melted in a separate furnace, is poured into the cylindrical sleeve and forced to take the shape of the die. This method eliminates the necessity for the injection mechanism to be immersed in molten bath. This method is used for applications that are too corrosive for immersion of design.

No matter what the techniques or approaches die castings have, both provide the advantage of providing complex shapes with closer tolerances. Die casting provide parts which are durable, dimensionally stable, and have the feel and appearance of quality. Die castings do not consist of separate parts, welded or fastened together, the strength is that of the material, not that of threads or welds. Economically speaking, die casting is also very useful as it can be used in a wide range of applications.

Should you feel the urge to know more about the processes involved with an assurance of looking into a reputable company, feel free to visit, www.basicaluminum.com.

References:

die – http://thinkexist.com/dictionary/meaning/die/

casting – http://www.thefreedictionary.com/casting

http://www.thomasnet.com/articles/custom-manufacturing-fabricating/die-casting-types

http://www.answers.com/topic/hot-chamber-die-casting

http://www.asminternational.org/portal/site/www/AsmStore/ProductDetails/?vgnextoid=ca5166ecb9f1f110VgnVCM100000621e010aRCRD#details

http://www.deeco.net/for/advandie.htm

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Aluminum Die Casting Alloy Properties
There are many types of aluminum die casting alloy properties like zinc, lead, copper, silver, tin and aluminum. These alloys have different features and they are chosen depending on the manufacturer’s needs and requirements as well as the required outcome of the finished product. Each metal have specific casting features that make it perfect for a type of product yet sometimes even dangerous. While lead is easy to melt and find at hardware stores, the finished product or even during the process can harm anyone within the area and cause brain damage. Copper is also easy to find from scraps of electric wires as well as silver that may be more expensive than other metals. Casting aluminum, on the other hand is one of the easiest metals to deal with because it can be used for most casting processes.

 

Aluminum can be used for die casting, mold casting – even the permanent process, sand casting – where green sand or dry sand can also be used, plaster casting, investment and continuous casting. Other casting processes like lost foam, hot iso-static pressing or squeeze casting can also be used for casting aluminum. Most manufacturing companies ideally choose aluminum to mold their products because it is the most economical alloys that they can use for many products. Not only that, aluminum holds interesting features in an alloy that will ensure their product’s quality.

Casting aluminum is easier than most because it is lightweight and durable. Aluminum doesn’t bend as easily to heat or cold and it surpasses all seasons. It is also quite strong and cheaper compared to other alloys, and easier to find a supplier, thus bulk production manufacturers have no problem searching for alternative suppliers in case the current distributor runs out of stock. Aside from being strong and durable, aluminum can also be molded and shaped into many things.

Other alloys can also be considered to be good casting metals, but not all of them will reap an outcome the same as that of aluminum. About half the things in a household are made up of aluminum and usually these furniture and fixtures will last many years before breaking down. Aluminum is also best used for collectibles, especially toys or items for children because they portray less risks than other alloys like lead which is cancerous. As a manufacturer choosing the right alloy for your production is necessary for successful processing and manufacturing.

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Economics and Processes of Diecasting
Today, almost everything we use is made out of metal. What we don’t know is how the process takes place in creating, molding and designing a by-product of different kinds of metal. Unlike clay pots where clay is molded by human hands on a potter’s wheel, metal cannot go through the same method – most probably because metal isn’t the easiest to mold nor is it the best idea to touch either especially when metal is all hot and liquid-like.

These metal items we use are molded through the process of die casting. Diecastings undergo a complicated process but is mostly automated. There is a wide variation of metal that can be made into die casts like aluminum, zinc, copper and etc, but the metal depends on the desired finished product. In the die casting process, metal, in it melted form, is poured into a mold cavity which is shaped not necessarily like the finished product but similar to it with space for designing and further molding before sending it off as completely finished.

While diecastings are in demand and have a lot of advantages for a manufacturing company, there are also some disadvantages that die casting companies have to be aware of and will have to make do or find ways to lessen the disadvantage.

The main disadvantage of die casting is probably the fact that the whole process is very expensive. The initial cost of the whole process – machines, metal – anything required to die cast are quite costly thus to save up on the costs acquired in die casting and make it an economical process, volume manufacturing has to be done. This way, at least you’ll be producing more by-products and saving money. Diecastings are also limited only to high fluidity metals so choosing the right metals for a specific product has to become part of the daily process. Casting weights also have limitations – casts must not be less than 30g and yet, not more than 10kg. Aside from weight limitations, casting also limits on the thickness and size of the die cast product, only allowing not more than 600mm or 24 inches and the thickest part must not exceed 13mm or 0.5 inches.

Reputable diecastings manufacturers are astute in careful planning for financial economical processes, as well as proper utilization of material resources. It is best to trust only reliable die casting companies so not to waste money and time for errors.

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Die Castings Experts
In the heart of Cleveland, Ohio is a die castings expert that has remained undaunted in rendering its services since 1945 to people who have sought for the best products in, around and off the shores of the United States. A lot of unscrupulous individuals have posed claims that the quality they assure in their castings are outstanding but what is strikingly exclusive is that it has already cemented its place in the industry.

The integrity is unmatched as every key ingredient necessary in building the name and in manufacturing products have been specifically followed. The cost, delivery and sensitivity to premium work have all been displayed by the business group. As expected, with 55,000 square feet area at hand, prospective clients are assured that quality assurance is given prime importance. Furthermore, there is no problem when it comes to accessibility as the place boasts of main thoroughfares that will easily transport and deliver the goods.

Ultimately, what is offered is high pressure aluminum die castings. As known to many, the use of different casting alloys plays a crucial role in meeting the demands of the market; whether it is used as part of the engineering products or for assembly and plating purposes, the said products should still reflect cost efficiency. People should get their money’s worth especially since the castings are produced in large volumes. Rest assured that despite the massive orders received, defects are thoroughly inspected from mis-runs to cold shuts. Human errors brought about by excessive lubricant, sharp corners as well as poor gating are reviewed every now and then by qualified technicians.

With the high capital cost derived from purchasing the casting equipment, expect that the processes involved in the die castings are optimized and that these undergo innovations when necessary. The sincerity of personnel in delivering unparalleled professionalism will always be warranted. Therefore, customers as well as long-time patronizers will not need to worry about beating deadlines and missing out on several important details that might have been dismissed earlier on in the stipulated contract. Be convinced with your answer to the quest for the perfect die castings firm.

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Die Casting
The die casting method or process can be applied to a wide range of metals that can be molded and utilized for several other products. Since metal is the main variable in creating die casts, most products undergoing die casting are considered to be strong, bearing long service lives, easy access to building products with accurate measurements and all the other advantageous features metal can bring to a product. Die castings undergo a complicated process but is mostly automated. There is a wide variation of metal that can be made into die casts like aluminum, zinc, copper and etc, but the metal depends on the desired finished product. In the diecasting process, metal, in its melted form, is poured into a mold cavity which is shaped like the finished product.

Today, almost everything we use is made out of metal. What we don’t know is how the process takes place in creating, molding and designing a by-product of different kinds of metal. Unlike clay pots where clay is molded by human hands on a potter’s wheel, metal cannot go through the same method – most probably because metal isn’t the easiest to mold nor is it the best idea to touch either especially when metal is all hot and liquid-like. These metal items we use are molded through the process of diecasting.

While diecastings are in high demand and have lots of advantages there are also some disadvantages that diecasting companies have to consider.

The main disadvantage of diecasting is the fact that the whole process is very expensive. The initial cost of the whole process – machines, metal – anything required to die cast are quite expensive thus volume manufacturing has to be done. This way, manufacturers are producing more by-products and saving money. Diecastings are also limited only to high fluidity metals so choosing the right metals for a specific product has to become part of the daily process. Casting weights also have limitations – casts must not be less than 30g and yet, not more than 10kg. Aside from weight limitations, casting also limits on the thickness and size of the die cast product, only allowing not more than 600mm or 24 inches and the thickest part must not exceed 13mm or 0.5 inches.

Having this in mind would mean careful planning for financial and material resources. It is important to choose a trusted die casting manufacturer who knows the best way to customize production process for the advantage of the part or product they intend to make.

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Copper Costituent In Die Cast Alloy
Most commercial die cast alloys contain less than 5% copper
Most commercial die cast alloys contain less than 5% copper; up to this level, a solid solution of copper in aluminum is formed on solidification but on further cooling, the CuAl2 compound is precipitated from solution.

Generally copper is added to aluminum alloys to improve strength and hardness: between 2.8 to 5% is necessary to give good response to heat treatment. Lower copper contents have some hardening effect but the alloys are not responive to heat treatment. Corrosion resistance is reduced by copper, and for optimum resistance the copper content should be less than .05%. As copper content increases, there is a gradual increase in corrosion attack.

 

Street, A.C. (1977) The Die Casting Book. Red Hill, England. Portcullis Press, Ltd