Introduction
High-pressure aluminum die-casting is suitable for producing large-scale, high-precision, high-density aluminum castings, such as automobile hoods, aluminum frames, etc. Due to its advantages of high efficiency, high precision and good surface finish, high-pressure aluminum die casting is also suitable for the production of electrical instruments, radio communications, televisions, computers, agricultural machinery, medical equipment, washing machines, refrigerators, clocks, cameras, architectural decoration and Components for various products such as daily hardware.
For a variety of goods, high pressure aluminium die casting is a flexible and effective production method that has several advantages. Using this process, molten aluminium is injected under high pressure into a steel mould, producing intricate, detailed pieces with remarkable accuracy and quality. We shall examine the many product categories in this post that may profit tremendously from high pressure aluminium die casting.
Что такое литье алюминия под высоким давлением?
The technique of making high-pressure aluminium die casting involves injecting molten aluminium under high pressure into a steel mould or mould using a die-casting equipment to create the finished aluminium casting. Die casting and high pressure casting are some names for this technique.
The high-pressure aluminium die-casting technique involves filling the die-casting mould cavity with liquid aluminium, liquid metal, or alloy comprising reinforcing phases quickly and under high pressure. The liquid then solidifies under pressure to make a casting. The metal filling speed is between 0.5 and 120 m/s, and the typically employed pressure range is 4~500 MPa. The two main distinctions and significant characteristics of the die casting process are high pressure and fast speed, as the molten metal fills the mould cavity in an average of 0.01-0.2 seconds.
This casting technique is appropriate for producing large-scale aluminium castings, such as automobile hoods and aluminium frames, and may provide high-density and high-precision aluminium castings. In addition, since aluminium die castings can be formed into a variety of more intricate forms, they can also be created with greater smoothness and accuracy, which lowers the amount of metal allowance and machining required for castings and saves money on labour, metal materials, and power.
High-pressure aluminium die-casting does, however, have several drawbacks, including expensive equipment requirements, incapacity to make big parts, and unsuitability for thin-walled component production. By contrast, low-pressure aluminium die-casting has the benefits of simple operation and control, less expensive equipment, and the ability to produce components with thin walls. Its cost is greater, it cannot create huge components, and its production efficiency is relatively poor. weakness.
What product types can it be applied to?
Automotive Parts
High pressure aluminium die casting is a major component used by the automobile industry to produce a variety of parts and components. For automotive applications, this manufacturing technique provides the strength, durability, and dimensional precision needed for everything from engine blocks and cylinder heads to gearbox cases and suspension components. Aluminum’s lightweight properties also enhance a vehicle’s overall performance and fuel economy.
Электроника
In the electronics sector, high pressure aluminium die casting is commonly utilised to produce enclosures, heat sinks, and other components. Aluminium is a great material for dispersing heat and guaranteeing the appropriate operation of electronic equipment because of its exceptional thermal conductivity and electrical characteristics. The design freedom of electrical devices is further enhanced by the capacity to build thin barriers and complicated forms.
Промышленное оборудование
High pressure aluminium die casting is a common method used by producers of industrial equipment to create robust and dependable components. Aluminium components provide outstanding corrosion resistance, a high strength-to-weight ratio, and dimensional stability for everything from pumps and valves to compressors and turbines. These characteristics make them ideal for demanding industrial applications where durability and performance are essential.
Aerospace
Strong and lightweight components are needed by the aircraft industry, and high pressure aluminium die casting satisfies this need. This procedure is used by aircraft manufacturers to make parts including structural components, brackets, and engine housings. Because of its low weight and remarkable strength and rigidity, aluminium is a perfect material for aerospace applications where weight reduction is essential for performance and fuel economy.
Sports and Recreation
Sports and leisure are another sector that makes extensive use of high pressure aluminium die casting. Aluminium is a common material for fishing reel components, camping gear, bicycle frames, and golf club heads due to its lightweight and sturdy qualities. Manufacturers are able to optimise performance and functionality while keeping the appropriate weight and strength characteristics due to the capacity to develop complicated designs and complex forms.
Advantages and Disadvantages of High Pressure Aluminum Casting Die
High pressure aluminium die casting has the following benefits:
- great accuracy and density: High-pressure injection may guarantee great precision and density in aluminium castings, resulting in the production of higher-quality aluminium castings.
- Appropriate for producing big aluminium castings: High-pressure aluminium die-casting is appropriate for producing large aluminium castings, including automobile hoods and aluminium frames, since it can produce more pressure.
- High production efficiency: By continually producing large numbers of items, high-pressure aluminium die-casting may lower production costs and increase production efficiency.
- Simple and easy to run: High-pressure aluminium die-casting is a comparatively straightforward process to operate, which may lower operational difficulties and increase production stability.
Nevertheless, there are several drawbacks to high-pressure aluminium die casting as well.
- Exorbitant equipment expenses Equipment costs are significant for high-pressure aluminium die-casting because it needs high-pressure die-casting machines and matching moulds.
- Not appropriate for producing thin-walled parts: High-pressure aluminium die-casting produces more pressure, which might cause thin-walled components to break or distort. For this reason, it is not appropriate for producing thin-walled parts. portion.
- Unable to make huge parts: While large aluminium castings may be made using high-pressure aluminium die casting, the production of extremely large components may be restricted by moulds and equipment.
The difference between high pressure die casting and low pressure die casting
The pressure and filling speed variations are the primary distinctions between high-pressure and low-pressure die casting. Both low-pressure and high-pressure die casting have benefits and drawbacks, therefore the best method for a given application will depend on the demands and intended uses of the final product.
The pressure in high-pressure die casting is comparatively high; it typically ranges from hundreds to thousands of kPa and sometimes reaches tens of thousands of kPa. Simultaneously, the filling speed is equally rapid, often ranging from 10 to 50 m/s, and sometimes exceeding 100 m/s. The two main advantages of high-pressure die-casting are its ability to create castings with accurate dimensions and a smooth surface finish: high pressure and high speed filling of die-casting moulds. Additionally, the strength and hardness are stronger—typically 25–30% higher than with sand casting. Furthermore, the die-casting mould used in high-pressure die-casting is long-lasting, capable of producing intricate and thin-walled castings, has a high production efficiency, and is simple to automate and mechanise.
Low-pressure die casting, on the other hand, typically operates at pressures between 0.01 and 0.05 MPa. In general, the filling pace is similar to gravity pouring and is somewhat sluggish. poor-pressure die casting has a poor surface polish and a low production efficiency because to its low pressure and sluggish filling characteristics. In general, it is not appropriate for sections with thin walls.
Заключение
several advantages are provided by high pressure aluminium die casting for a broad variety of products in several sectors. It is a favoured manufacturing technique for electronics, sports and leisure items, industrial equipment, automotive parts, and aerospace components because of its superior quality, accuracy, and adaptability. Utilising the benefits of high pressure aluminium die casting, producers may produce trustworthy and creative goods that satisfy the needs of the contemporary market.
