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On the basis of the traditional die-casting process, se […]
On the basis of the traditional die-casting process, several improved processes have been born, including a non-porous die-casting process that reduces casting defects and eliminates pores. Mainly used for processing zinc, it can reduce waste and increase the yield of direct injection process.
Advantages of die casting include excellent dimensional accuracy of the casting. Usually this depends on the casting material, typical values are 0.1mm error at the initial 2.5cm dimension and 0.002mm error for each additional 1cm. Compared with other casting processes, its casting surface is smooth and the fillet radius is about 1-2.5 microns. Castings with a wall thickness of about 0.75 mm can be produced relative to sandbox or permanent mold casting. It enables direct casting of internal structures such as wire jackets, heating elements, high-strength bearing surfaces. Other advantages include its ability to reduce or avoid secondary machining, high production speeds, casting tensile strengths of up to 415 MPa, and the ability to cast high-flow metals.
The biggest disadvantage of die casting is its high cost. Casting equipment as well as molds and mold-related components are expensive relative to other casting methods. Therefore, it is more economical to produce a large number of products when manufacturing die castings. Other disadvantages include: the process is only suitable for relatively fluid metals, and the casting mass must be between 30 grams and 10 kilograms. In normal die casting, there will always be voids in the last batch of castings cast. Therefore, no heat treatment or welding can be performed, because the gas in the gap will expand under the action of heat, causing internal micro-defects and peeling of the surface.