Aluminum Alloy High-pressure Die-cast Multifunctional Connection Bracket
It is suitable for industrial machinery and equipment (such as automated production line connectors, robotic arm fixed components), and automotive parts (suspension system brackets, interior connectors) as structural connections or force-bearing support components. It relies on the lightweight aluminum alloy and the efficient molding advantages of the die-casting process to achieve stable assembly and functional support.
classification：
Die Casting Parts
Keywords:
Jiesen
Product Details
1. Principle of die-casting process
Die casting is a metal forming process that uses high pressure to press molten metal into a mold cavity at high speed to obtain high-precision, complex-shaped castings. Its core features are high pressure (tens to hundreds of MPa) and high speed (metal filling speed can reach 10~50 meters/second). It is widely used in automobiles, aerospace, electronics, home appliances and other fields.
2. Main steps of die casting process
"Main steps:
1. Mold preparation: preheat the mold (usually 150~250℃), spray parting agent (lubrication, heat dissipation, mold protection).
2. Molten metal: The alloy is melted and kept at a suitable temperature (for example, aluminum alloy is about 650~720°C), followed by degassing and slag removal.
3. Injection: Mold clamping → injection punch pushes molten metal to fill the mold → pressure holding (several seconds to tens of seconds) → cooling and solidification.
4. Demolding: the movable mold moves, the ejection mechanism ejects the casting, and at the same time cleans the mold cavity to prepare for the next cycle.
5. Post-processing:
Surface treatment: shot blasting, electroplating, painting, etc.;
Defect repair: welding repair (for non-stressed parts), plastic surgery;
Inspection: dimensional measurement, X-ray flaw detection (detection of internal pores, shrinkage porosity). "
3. Key process parameters of die casting:
| pressure | Injection specific pressure: the pressure per unit area, which affects the mold filling ability and the density of the casting. Aluminum alloy: 30~100 MPa; Copper alloy: 50~150 MPa. | |
| Holding pressure: Maintain pressure until the casting solidifies to prevent shrinkage cavities. | ||
| temperature | The temperature of the molten metal: If it is too high, it will easily stick to the mold and the grains will become coarse; if it is too low, it will easily cause cold insulation and insufficient pouring. | |
| Mold temperature: affects the cooling rate and mold life, and needs to be adjusted through the temperature control system. | ||
| Charging speed | High-speed mold filling can reduce the cooling of the molten metal, but it is easy to entrain gas and form pores (the main defect of traditional die-casting). | |
4. Materials, characteristics and applications suitable for die casting
| Materials suitable for die casting process | Material characteristics | Application |
| Aluminum alloy | It has the characteristics of low density, high strength, good plasticity, and good corrosion resistance. It also has a relatively low melting point and good fluidity during the die-casting process. It can quickly fill the mold cavity and obtain castings with complex shapes and high precision requirements. Commonly used die-cast aluminum alloys include Al-Si series (such as ADC12), Al-Mg series, etc. |
1. Widely used in engine parts (such as cylinder block, cylinder head cover, etc.), transmission system (such as transmission housing), chassis components (such as wheel hubs, steering knuckles, etc.) and body structural parts (such as door inner panels, trunk inner panels, etc.). These components require high strength, stiffness and heat resistance. Aluminum alloy die castings meet these needs while also reducing vehicle weight and improving fuel economy. 2. Can be used to manufacture mobile phone casings, tablet computer casings, etc. The high thermal conductivity of aluminum alloy helps dissipate heat from electronic equipment and ensures the stable operation of the equipment; 3. The shells, stents and other components of some small medical devices are manufactured using aluminum alloy die-casting processes. The biocompatibility and processability of aluminum alloys make them suitable for use in the field of medical equipment. At the same time, their good strength and corrosion resistance can also meet the requirements of medical devices. |
| zinc alloy | It has a low melting point, excellent fluidity, and is easy to form, allowing very fine details and thin-walled structures to be cast. At the same time, zinc alloy has good machining performance, and the surface can be subjected to various surface treatments such as electroplating and spraying to obtain good appearance quality. Common zinc alloys include ZA-8, ZA-12, ZA-27, etc. |
1. Commonly used in automotive interior parts, such as dashboards, air conditioning vents, door handles, etc. The good surface treatment properties of zinc alloy can make these interior parts rich in color and texture, improving the beauty and quality of car interiors. 2. It is a commonly used material for manufacturing various hardware accessories, such as locks, handles, decorative buckles, etc. Zinc alloy can be used to manufacture products with complex shapes and high precision requirements through the die-casting process, and the surface can be electroplated, polished and other treatments to give it a beautiful and durable appearance. |
| Magnesium alloy | It is the lightest metal structural material in practical applications. It has a series of advantages such as high specific strength and specific stiffness, good damping and machinability, and good electromagnetic shielding. Magnesium alloys also have good fluidity during the die-casting process. Commonly used die-cast magnesium alloys include AZ91D, AM60B, etc. |
It is widely used in notebook computers, digital cameras and other products. The magnesium alloy shell can effectively shield electromagnetic interference and protect electronic components, and its lightweight characteristics are also in line with the development trend of portability of electronic products. |
| copper alloy | Good electrical and thermal conductivity, corrosion resistance | Electrical connections, valves, pipe fittings |
| Lead alloy | High density, corrosion resistance, easy to process | Battery plates and counterweights |
| tin alloy | Low melting point, corrosion resistance, non-toxic | Food packaging, bearing materials |
| Nickel Alloy & Titanium Alloy | High temperature resistance and corrosion resistance | Aerospace and Chemical Industry |
5. Common defects and solutions
| Defect type | Reason | Jiesen solution |
| pores/shrinkage holes | Filling speed is too fast, mold exhaust is poor, and pressure holding is insufficient | Reduce the filling speed, add an exhaust slot, and increase the holding pressure |
| Cold insulation | The temperature of the molten metal is too low, the filling speed is too slow, and the mold temperature is low | Increase molten metal/mold temperature and optimize runner design |
| Sticky mold | Mold surface wear, parting agent not sprayed, molten metal temperature too high | Polish the mold surface, standardize the spraying process, and control the temperature |
| Size out of tolerance | Mold wear, insufficient mold clamping force, insufficient cooling time | Regularly repair the mold, check the mold clamping force of the equipment, and extend the pressure holding time |
6. Development trends of Jiesen die-casting technology
1. Vacuum die casting
Before filling, the air in the mold cavity is extracted to reduce pores, so that the casting can be subjected to T6 heat treatment to improve the mechanical properties and is suitable for parts with high requirements (such as automobile structural parts).
2. Semi-solid die casting
Using semi-solid metal slurry (solid-liquid mixed state) for die casting, mold filling is smooth and pores are reduced, and high-performance castings (such as aerospace components) can be produced.
3. Intelligent die-casting technology
Combining sensors and AI algorithms to monitor pressure, temperature and other parameters in real time, optimize process parameters and achieve "black light factory"-style automated production.
3. Mold material innovation
Develop new mold steels that are resistant to high temperatures and wear (such as nano-coating treatment) to extend mold life and reduce production costs.
4. Green die-casting process
Promote fluorine-free and phosphorus-free environmentally friendly parting agents and waste heat recovery systems to reduce energy consumption and pollution, in line with the trend of sustainable manufacturing.
Summary
Pressure casting is an efficient and precise molding technology in modern manufacturing, especially suitable for mass production of complex metal parts. Although there are limitations such as high mold cost and internal pores, it is continuously expanding its application boundaries through technological innovation (such as vacuum die-casting and semi-solid molding). In the future, with the development of new energy vehicles, 5G communications and other industries, the die-casting process will continue to make breakthroughs in the direction of lightweight, precision and intelligence, becoming one of the core technologies of high-end manufacturing.
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