Our Pressure Die Casting Process
Precision & Efficiency
Pressure Die Casting is a high-precision manufacturing process where molten metal is injected into a mold under high pressure. This ensures complex shapes, excellent surface finish, and superior strength with minimal waste. The process involves metal melting, high-pressure injection, rapid cooling, ejection, and finishing for flawless components.
At [ Vision Metal Cast], we deliver cost-effective, high-quality die casting solutions for industries like automotive, aerospace, and electronics. Contact us today!
Cold Chamber Pressure Die Casting is a process used for high-melting-point metals like aluminum and copper alloys. Unlike the hot chamber process, where the molten metal is in direct contact with the machine, in the cold chamber process, the metal is melted in a separate furnace and then poured into the shot sleeve for injection into the mold.
Material Selection and Spectro Testing
Raw Material Selection
We use high-grade aluminum alloys that meet industry standards for strength, durability, and corrosion resistance.
- The aluminum ingots are inspected before melting to ensure they are free from impurities and defects.
Spectro Testing with Moose Machine
Before casting, we conduct a spectrometric analysis using a Moose Machine to verify the chemical composition of the aluminum alloy.
This testing ensures that the alloy meets required specifications for elements like Si, Mg, Fe, Cu, Zn, Ti, Mn, and Al.
This process helps in maintaining consistent mechanical properties and ensuring high-quality finished products.
Melting and Degassing
Melting
The aluminum is melted in an external furnace at approximately 680–750°C.
- Proper furnace maintenance is essential to ensure consistent melting efficiency and prevent contamination.
- Alloy composition monitoring is conducted to maintain the desired mechanical properties and casting quality.
Degassing & Fluxing
Degassing: We use inert gases (argon or nitrogen) to remove dissolved hydrogen, which can cause porosity in the final casting.
Fluxing: Specialized fluxes are added to remove oxides and other impurities to maintain metal purity.
- Filtration: Before casting, the molten aluminum is passed through ceramic filters to remove remaining inclusions and ensure superior metal cleanliness.
Cold Chamber Die Casting Process
Metal Transfer to Shot Sleeve
The molten aluminum is poured into the cold chamber shot sleeve using an automated ladle or manually, depending on the job size.
Injection into Mold Cavity
A high-pressure hydraulic piston forces the molten aluminum into the steel mold at high speed and pressure.
The pressure ensures that the metal fills all intricate mold details and minimizes shrinkage defects.
Solidification & Ejection
Once the aluminum solidifies in the mold, the die halves separate, and the casting is ejected using ejector pins.
The cooling time is optimized based on part thickness and mold temperature control.
Machine Capacities & Operations
Each machine is used based on the size, weight, and complexity of the aluminum die-cast component required.
Technocast Machines
| Machine Capacity | No. of Machines | Max Job Weight |
|---|---|---|
| 120 Ton | 2 | 1 kg |
| 180 Ton | 2 | 1.5 kg |
Yamoto Machines
| Machine Capacity | No. of Machines | Max Job Weight |
|---|---|---|
| 250 Ton | 1 | 4 kg |
| 450 Ton | 1 | 7 kg |
Post-Casting Operations
Trimming & Deburring
Excess material from casting (flash, runners, and sprues) is removed using trimming presses and manual grinding tools.
Heat Treatment (If Required)
Certain components undergo T6 heat treatment to enhance their mechanical properties like strength and hardness.
Surface Finishing
Shot Blasting: Removes surface imperfections and provides a uniform matte finish.
Machining: CNC machining is used for precise finishing and achieving tight tolerances.
Coating & Painting: If required, components are coated with powder coating or anodizing for better corrosion resistance.
Quality Control & Inspection
Visual & Dimensional Inspection
Every casting is visually inspected for defects like porosity, cracks, and surface irregularities.
Dimensional accuracy is checked using CMM (Coordinate Measuring Machine), Vernier calipers, and micrometers.
Pressure Leak Testing (If Required)
Components used for hydraulic and pneumatic applications undergo pressure leak testing to ensure no leakage under operating conditions.
Spectro Re-Verification
Final products are rechecked using Moose Machine spectro analysis to ensure chemical consistency.
- Spectro Re-Verification: Final products are rechecked using Moose Machine spectro analysis to ensure chemical consistency.
Packaging & Dispatch
Degreasing & Cleaning
Each component is thoroughly degreased to remove any residual oil, dust, or contaminants from the manufacturing process.
If necessary, components undergo ultrasonic cleaning for superior cleanliness.
Packing Methods
Parts are packed based on size, weight, and customer requirements:
Small components: Packed in anti-static plastic bags or shrink wrap.
Medium-sized components: Wrapped in bubble wrap or foam sheets and placed in reinforced cardboard boxes.
Large components: Placed in wooden crates or metal containers for safe transit.
Corrosion-resistant coatings are applied if required, and silica gel packs are added to control moisture.
Labeling & Documentation
Each package is labeled with:
Product name & specifications
Batch number & date of manufacture
Customer order details
Handling & storage instructions
Quality assurance certificates and material test reports are included for verification.
Logistics & Dispatch
Products are dispatched using trusted logistics partners with options for:
Domestic shipping (road transport, rail freight)
International shipping (air cargo, sea freight)
Tracking details are shared with clients for real-time monitoring of shipments.
Proper documentation, including invoices, packing lists, and compliance certificates, is provided.
Our Products
