Basics of Aluminum Die Casting Process

This process involves several key steps, each of which helps to meet exact specifications. The process starts with mold creation. At the same time, this mold can quickly produce thousands of castings. These molds can be opened and closed to inject molten aluminum and eject the final product. The cycle begins by clamping the two halves of the mold tightly together, then injecting molten aluminum, which then quickly solidifies.

Step 1: Mold Preparation and Clamping

The first step in the aluminum die casting process is to prepare and clamp the two halves of the mold. The mold is usually made of steel and includes two halves to allow the finished casting to be removed. Next, the mold is clamped in the casting machine (one half is fixed and the other half is movable) ready for the next step.

Step 2: Molten Aluminum Injection

Aluminum melted in a separate furnace is scooped into the cold chamber of the casting machine. Here, cold chamber die casting is suitable to prevent machine damage. The molten aluminum is then injected into the mold cavity under high pressure, where it quickly solidifies.

Step 3: Cooling and Solidification

The next step is cooling and solidification. This stage is crucial because it determines the final properties of the casting. Molten aluminum begins to cool immediately upon contact with the inner surface of the mold and solidifies into the shape of the mold cavity. Cooling time control is critical to ensure that the aluminum solidifies evenly and prevents defects such as warping or internal porosity.

Step 4: Ejection of cast aluminum parts

Once the aluminum solidifies, the final step in the die casting process is the ejection of the casting. Here, part injection involves hydraulic cylinders or other mechanisms for precise movement. The solidified aluminum part is then ejected from the mold cavity, usually with the help of ejectors integrated into the mold design.

Step 5: Trimming and finishing

After ejection, trimming and finishing are usually performed to remove excess material and improve its appearance. It may include cutting off sprues, flash, or other unwanted parts. Then, finishing techniques such as grinding or polishing are applied to obtain the desired surface finish. This step is critical to ensure that the part meets all specifications and is ready for its intended application.

Overall, it is necessary to follow a technical path from the design stage to the manufacturing stage to reduce casting defects. Avoid deviations in the early stage and avoid complexity in the later stage.