Automotive Die Casted Components

Automotive Die Casted ComponentsABOUT The earliest examples of die casting by pressure injection - as opposed to casting by gravity pressure - occurred in mid 1800's. A patent was awarded in 1849 for first manually operated machine for casting printing type. The process was limited to printer's type for next 20 Yrs. The first die casting alloys were various compositions of Tin and Lead but use declined with introduction of Zinc & Aluminum Alloys in 1914.The die casting processes have evolved from the original low pressure injection method to techniques including: High-pressure casting at forces exceeding 4500 pound/sq.inch Squeeze casting & Semi Solid Die Casting These modern processes are capable of producing high integrity, near net-shape casting with excellent surface finish. TYPES Pressure die casting industry has two types of pressure die as processing: High pressure Die Casting The most common used process, in which molten aluminum is injected at High pressure into a metal mould by a hydraulically powered piston , the machinery needed for the process can be very costly & this is economical only when used for mass production. Low Pressure Die casting Commonly used for Large Non-critical Parts, uses a die which is filled from a pressurized crucible underneath, the process is suitable particularly for production of rotationally symmetrical products. Only Fundamental difference in die casting machines is the method used to inject molten metal into a die. The two methods are: Hot Chamber Used primarily for Zinc, Copper, Magnesium, Lead and other low melting point alloys that do not readily attack and erode metal pots, cylinders and plungers. Cold Chamber They are used for the molding of alloys having high melting point such as aluminum and other like wise. ADVANTAGE Die Casting is an efficient economical process offering a broader range of shapes and Components than any other manufacturing technique. Parts have longer service life and may be designed to complement the visual appeal of surrounding parts. The Products are durable and dimensionally stable, while maintaining closer tolerances. They are also heat resistant. Vs Plastic Molding Die casting Produces stronger Parts with Closer Tolerances that have greater stability and durability and parts have greater resistances to temperature extremes and superior electric properties. Vs Sand Casting Die casting Produces parts with thinner walls, closer dimensional limits and smother surfaces. The production rate is faster as labour cost and finish costs are low. Vs Permanent Mold Die casting offers the same advantage over the permanent molding as for low production costs with high production rate and tight tolerance. Vs Forging Die casting produces more complex shapes with closer tolerances, thinner walls and lower finishing cost. Cast coring holes are not available with forging. We at MK have HPDC Machines Ranging from 80 Tons to 400 Tons Capacity, which are able to maintain tighter tolerances and more detail than Low Pressure Die Castings because the extra pressure is able to push the metal into more detailed features in mould. Our High Pressure Die castings have Excellent Surface Finishes that are consistent dimensionally with precision features and minimum draft. We are one stop sourcing for engineered & aluminum die casting.