Precision Die Casting
Die casting is the process of forcing molten metal into a mould cavity under high pressure. In precision die casting, the mould cavity is usually made with two steel dies that have been created into the desired shape by a machine.
At EKO, die castings are manufactured with non-ferrous metals such as aluminium, zinc, and tin-based alloys. The type of metal that is being cast determines the type of machine used (hot chamber/cold chamber) to make the cast.
Die casting is a manufacturing process that is suitable for high volume items. As metal dies and casting equipment make up a large part of capital costs, the incremental cost per item tends to be very low.
Our precision die-casting process ensures that the products that we manufacture have excellent surface finishing and good dimensional consistency with precise measurements.
Die Casting Material
Alloys that are suitable for die casting are those that are corrosion resistant and have optimal density. Our engineers assess the mechanical properties such as strength, hardness and elongation when picking the right alloy to use for your die-cast.
The most common die casting alloys are aluminium, magnesium, zinc and copper.
Here at EKO, we use a variety of Aluminium & Zinc materials to support customer requirements in order to meet the quality of the specified products
Aluminium DIE CASTING
Aluminium die casting alloys or so-called “ADC/LM” (follow with the code ADC12/LM1) are lightweight. It offers good corrosion resistance, ease of casting, good mechanical properties and dimensional stability. It also has excellent shielding properties, high electrical conductivity and is durable enough to achieve high quality finishing characteristics.
Zinc Die casting
Zinc or so-called “Zamak” have the high strength and hardness with an excellent electrical conductivity. Apart from this, Zinc has characteristics such as high thermal conductivity, accuracy and stability during casting. It has an excellent thin wall capability and resulting to the ability to achieve high quality finishing characteristic.
Precision Die Casting Process
- Clamping – The two halves of the die are clamped together with enough force to keep it secure when the metal is injected.
- Injection – Molten metal is injected into the die. The transfer method of the metal depends on whether a hot chamber machine or cold chamber casting machine is used.
- Cooling – The molten metal is allowed to cool and solidify when it enters the die cavity.
- Ejection – Once the cooling time has passed, the two halves of the die will be opened and the casting is pushed out with an ejection mechanism.
- Trimming – Excess material will be trimmed from the casting.
Types Of Die Casting
Hot Chamber Die Casting
In hot chamber die casting, the injection mechanism’s cylinder chamber is completely immersed in the molten metal. The direct immersion results in a fast, convenient mould injection that leads to high production rates.
Hot chamber die casting works well for items that use metals with low melting points such as zinc, lead and tin.
Cold Chamber Die Casting
In cold chamber die casting, the molten metal is ladled into the injection system. This means the injection mechanism is not immersed in molten metal.
Cold chamber die casting is used for alloys with high melting temperatures such as brass, aluminium, and magnesium.
The type of die casting needed is dependent on the project or product and its application. Our team at EKO will ensure that the right process is used for your application.
The manufacturing industries are constantly changing–there’s always a new technology promising to make manufacturing floors more efficient than ever. It also helps to keep abreast of technological developments and ensure that your business is taking advantage of the latest innovations to improve productivity.
HERE AT EKO, We do cast either in Aluminium or Zinc with our latest Hot & Cold Chamber Machine
Surface Improvement & Finishing Process
With robust technology in hand, EKO supports the secondary process with a variety of equipment to turn the castings into high quality products.
EKO also offer a variety of Surface finishing to every single part that we produce such as:
Lastly before we ship finishing parts out to customers, we offer in-house appearance add ons such as: