In the fields of automotive parts, 3C electronic casings, home appliance structural components, and new energy shell manufacturing, die-casting (high-pressure pressure casting, abbreviated as HPDC) is the core forming process for mass production of precision non-ferrous metal parts. Many procurement and product engineers only know that die-casting can produce complex thin-walled parts, but they are not clear about the underlying logic of high-pressure and high-speed filling, pressure holding and solidification. This often leads to unreasonable mold design and incorrect matching of process parameters, resulting in batch defects such as porosity, shrinkage, and deformation.
Die casting, also known as high-pressure pressure casting, is a near net forming metal manufacturing process that operates similarly to plastic injection molding. It involves instantly filling a steel precision mold cavity with molten liquid non-ferrous metal under high pressure (20-180MPa) and high speed (30-70m/s), maintaining pressure throughout the entire process until the metal is completely cooled and solidified. After opening the mold, it is ejected to obtain the finished casting.
Different from sand casting and gravity casting: gravity casting only relies on the self weight of the metal to fill the mold, with weak forming ability and low accuracy; Die casting relies on mechanical high-pressure forced filling, which can stably form 0.5mm ultra-thin walls, complex curved surfaces, small buckles, and micro threaded structures, with high dimensional accuracy and smooth surfaces. The subsequent machining volume is extremely small, making it the preferred process for large-scale precision parts.
Mainstream compatible alloys: aluminum alloy (ADC12, A380), zinc alloy (Zamak3/5), magnesium alloy, rarely used for high melting point metals such as steel. Die casting equipment is divided into two core types: hot chamber die casting machines and cold chamber die casting machines, which have completely different working principles and applicable alloys.