HIGH PRESSURE ALUMINUM CASTING

High pressure aluminum casting at HESEM Vietnam

We design high pressure aluminum casting molds and mold machining. The mold after machining will be sent to a high pressure aluminum casting partner. The sample product after the molding process is checked by our engineer against the requirements to modify the mold if necessary. Then we process and send it outside for finishing: anodize, dip paint, powder coating…

Factors affecting the price of aluminum casting parts

The aluminum casting sample will be sent to the customer for quality assessment as well as the control sample to have a basis for quality control later. The monthly quantity of aluminum casting can meet from 1000 to 50.000 products/month. For products that do not require machining, we can supply 100.000 products per month.

The cost of aluminum pressure casting products depends on the number of products cast in a machine shift, the volume of castings, and the complexity of castings:

– The weight of casting parts 

Input materials are aluminum ingots with CO and CQ certification. We say no to casting aluminum scrap. If the casting volume is large, the casting unit price per kg will be cheaper. We calculate the casting price with the input material being originating goods. Quality assurance of castings.

Aluminum Ingot For High Pressure Aluminum Casting
The aluminum billet for high-pressure aluminum casting

– Amount of casting parts arranged in a mold 

The number of parts produced in a machine shift depends on the number of parts arranged on a mold. If the product is not bulky, we will be able to arrange many products in one mold, resulting in a much cheaper casting price. For the same casting volume, if the product is bulky (Example: large diameter aluminum ring) compared to the compact shape product, the casting price will be different.

– Complexity of  casting parts 

Parts with complex shapes or strict tolerances will have higher aluminum casting costs. The more complex products, the higher the mold price. At the same time, the error rate of aluminum casting products is also high. Based on actual products, we can work with customers to come up with options to modify the casting design to ensure the best casting mechanical properties as well as optimal cost.

In addition, the cost of aluminum casting parts also depends on the cycle time of casting machining, and surface finishing requirements such as sandblasting, dipping paint, and powder coating…

Contact us now for a consultation and quote.

Contact HESEM Precision Machining Factory

– Address: No. 1, Road No. 5, Vinh Phu, Thuan An, Binh Duong
– Phone: (+84)985994010
– Email: vannguyen@hesem.com.vn

Hesem . High Pressure Aluminum Casting

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To better understand aluminum casting. We go through the concept of high pressure casting, the classification of high pressure casting machine types, its advantages and disadvantages, and the application of each type in production. Thereby will help you choose the type of pressure casting that suits your needs.

What is high pressure casting?

     High pressure casting is a process in which molten metal is pushed into the metal mold cavity at a very high speed. After the metal has been filled, pressure is maintained on the liquid metal until solidification. After the metal solidifies, the mold is opened and the casting is ejected. 
     After the part is ejected, the mold is closed and ready for the next cycle. The injection of metal into the cavity is completed in a fraction of a second.
     While the molten metal remains in the mold cavity, extremely high pressure is maintained on the liquid metal to feed more liquid metal into the cavity to compensate for the shrinkage of the metal as it solidifies.
     Because the filling speed is very fast, the pressure casting method can cast products with a very thin thickness (0.5 mm) and complex shapes compared to the traditional gravity aluminum casting method. 

Classification of high pressure die casting machine

There are 2 types of pressure die casting machines: cold chamber high pressure casting machines and hot chamber high pressure casting machines

Cold Chamber Pressure Casting Machine

The cold chamber high-pressure casting machine has a metal melting furnace separate from the casting machine. The liquid metal is scooped by a manual or automatic bucket of the liquid metal from the furnace into a hydraulic piston-cylinder system to push the liquid metal into the mold cavity. Due to the heat loss in the process of scooping and pouring liquid metal, this type of casting machine is suitable for casting metal with high melting points such as aluminum, copper, and magnesium.
Cold chamber high pressure casting machines are also classified into cold chamber high pressure casting machines with vertical and horizontal filling systems.

Cold Chamber High Pressure Casting Machine (Video source: cwmdiecast.com)

Hot Chamber High Pressure Casting Machine

The hot chamber high pressure die casting machine has a hydraulic piston-cylinder system located in a liquid metal bath. The liquid metal is pushed directly into the high-pressure die from the liquid metal bath. By skipping the process of scooping and pouring liquid metal, this type of high pressure casting machine is suitable for casting metals with low melting temperatures such as zinc, lead, tin, and magnesium.

Hot chamber high pressure die casting machine (Video source: cwmdiecast.com)

Application of these types of high pressure casting machine

As analyzed above, a cold chamber high pressure die casting machine is suitable for casting high melting point metal and a hot chamber high pressure casting machine is suitable for casting low melting point metal.
Because the cold chamber high pressure casting machine has an additional intermediate stage of scooping and pouring, the productivity is not as high as that of the hot chamber high pressure casting machine.
The hot chamber high pressure casting machine has a size limit, so it is suitable for small parts. 
Particularly, magnesium can be cast in both types of machines. Small parts are cast in a hot chamber high pressure casting machine to improve productivity, while large parts are cast in a cold chamber high pressure casting machine.

The disadvantage of high pressure casting is that because the speed of filling metal into the mold is very fast, it will entrain air bubbles inside the casting. Although it cannot be seen with the naked eye, it still creates a certain porosity in the microstructure of the casting.

Nowadays, with the advancement of high pressure casting technology. A vacuum system is combined to suck all the air out of the mold cavity to limit the fear of mixing air bubbles into the casting. This technology creates products with high metal density and limited porosity, making the mechanical properties of castings significantly improved. This process is used to manufacture important light-alloy structural components, such as structural and safety components for cars, trains, etc.

Advantages and disadvantages of high pressure casting method

Advantages

  • Nice surface quality.
  • Capable of casting thin-walled, complex-shaped parts
  • With higher precision than sand casting, with low tolerance parts may not need re-machining, small diameter holes can be cast with precise tolerances.
  • Suitable for bulk mass production due to fast molding cycle of each product

Disadvantages

  • The mold price is high, and the initial investment cost is large, so it is only suitable for casting in quantity.
  • The casting size is limited by the size of the casting machine
  • Only suitable for non-iron metals
  • Expertise in pressure casting is required because pressure casting has the potential to create porosity in the casting. This porosity can be caused by wrong casting material selection, casting shrinkage, too fast or too slow filling speed, or improper mold design.

High pressure die-cast aluminum alloy

There are two basic groups of aluminum alloys used in high pressure die casting. Those are Al-9Si and Al-12Si. These two aluminum alloys make up the majority of aluminum alloys used for high pressure casting. There are many alloys for high pressure casting, but these alloys make up a much smaller percentage than the two above.

Commercial aluminum alloys represent the two above:
Al-9Si : LM24, A380, ADC8, CA313, AlSi8Cu3Fe
Al-12Si : LM6, A413, LM2, ADC12, AC3A, AlSi12

In aluminum alloy. In addition to the main metal component, aluminum, there is another substance to help strengthen the mechanical properties as well as the castability of
Silicon: making the molten metal more liquid, making the alloy easier to cast.
Iron: reduces the mold destruction rate of aluminum. If too much, the product will reduce ductility.
Copper increases the hardness of the casting. Excessive can lead to crack formation.
Magnesium: increase hardness. Excessive will cause breakage, and increase brittleness.

High pressure aluminum alloy component table

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