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  • Email:sale2@dgenchuang.com
  • Phone:+8613049349747
  • Address:101 Room, Building 1#, No 15, Changan Xingfa South Road,Changan Town, Dongguan City, Guangdong, China

REQUENTLY ASKED QUESTIONS Share Page +

We have compiled our answers to frequently asked questions in one easily accessible area so you can quickly find helpful information. This is a great place to start if you have general inquiries about our products.
  • +What Is Low Pressure Die Casting?

    Low Pressure Die Casting:This is a repetitive process where identical parts are cast by injecting molten under low pressure into metal dies. This process requires complex machinery similar to high pressure die casting.

     Advantages

    Fair production rates up to 30/ Hr

    Thin wall thickness possible (2-3mm)

    Better linear tolerances than gravity casting surface finish improved on gravity casting, but not up to pressure die casting standards

    High Yields possible as runners and risers not required

    Reduced finishing is required

    Pore free castings are obtainable

    Sand cores may still be used to allow complex castings die costs far lower than for pressure die casting

    Castings are heat treatable

    Limitations

    Size of casting limited by machine size

    Production rates not up to pressure die casting

    Feeding thin sections through thick sections is not recommended casting weight range 5 Kg - 25 Kg

    Approximate economical quantity range >1000 

  • +What Is High Pressure Die Casting ?

    High Pressure Die Casting: Pressure die casting is a repetitive process casting identical parts by injecting Aluminum into metal moulds at pressures in the order of 1000psi. Complex machinery and expensive tooling is required for this process.

    Advantages

    Production rates may be in the order of 200/ Hr

    Thin wall thickness at 1 - 2.5mm

    The best surface finish is produced by this method

    Very fine grain structure is obtainedThe castings have high strength in the as-cast condition

    Good linear tolerances and repeatable properties are obtained

    Limitations

    Size of castings limited by the machine

    Sound, thick sections are difficult to cast

    Core configuration may be complex to enable disassembly

    Porosity may become a concern

    High start up costs require long production runs to reduce the overall cost

    Castings cannot be heat treated casting weight range 0.01 Kg - 25 Kg

    Approximate economical quantity range > 10,000 per annum.

  • +What industries we serve?

    With nearly 15 years of design experience and expertise, ENCHUANG Precision Die Casting can handle any industrial die casting need skillfully and economically. J&M Precision Die Casting expertly produces Aluminum and Zinc Die Castings for a diverse array of industries including:


    • Aerospace
    • Agricultural
    • Appliances
    • Architectural
    • Automotive
    • Computer and Office Machines
    • Electronics
    • Electric Motor
    • Enclosures
    • Zinc plumbing tool, wrench used for drain
    • Lighting
    • Metal Working
    • Plumbing
    • Toys, Sporting Goods,
    • and Personal Goods
    • Transportation Industries


  • +What are the specific die casting products?

    ENCHUANG Precision Die Casting designs and creates Aluminum and Zinc Die Castings to exacting specifications. Some of the many industrial parts we die cast include:

    • Electric Motor Components
    • Locomotive Parts
    • Architectural Hardware
    • Decorative Hardware
    • Entrance and Exit Hardware
    • Plumbing Tools and Hardware
    • Security Hardware
    • Enclosures

    • Fluid Metering
    • Industrial Parts
    • Electro-Mechanical
    • Control Equipment
    • Head Lamp Buckets
    • Household and Commercial
    • Lighting Fixtures and Lamp Bases
    • Hubs (for Regulators for HVAC)






  • + Why choose zinc die casting?

    •Broad Market Appeal 
    Zinc die casting is ideal for products ranging from toys to electronics. components can be as simple as a sink faucet or as complex as a connector housing.   

    •Cost Savings 
    The advantages of zinc die casting are endless, as it is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Zinc die castings can provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap, threads can be cast both internally and externally, and parts can be cast with thin walls or other defining features. 

    •Precision 
    Zinc die casting produces multi-cavity, complex shapes within closer tolerances than many other production processes. In addition to producing high volume runs of virtually identical parts, it produces rugged heat and wear resistant parts that are dimensionally stable, while maintaining exceptionally close tolerances.   

    •EMI/RFI Shielding 
    The zinc die casting process produces parts with excellent EMI/RFI shielding characteristics, allowing the cast to act as an electrical ground for internal circuits. Zinc die castings are stronger than plastic parts with similar dimensions. Plus, because they do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.   

    •Outstanding Finish 
    Zinc die cast parts can be manufactured with smooth or textured surfaces, and are easily plated or finished with minimal surface preparation. 

    •Longer Tool Life 
    Thousands and in some cases millions of components of identical zinc die castings can be produced before new tooling is required.  
  • +Aluminum die casting provides several advantages over alternative processes and materials

    Aluminum is a versatile material used for many applications, giving mechanical designers significant advantages when creating lightweight parts that withstand high temperatures.  Aluminum die casting is often used in the automotive industry as a light and durable alternative to other metals while retaining maximum stability in thin walls. It’s an exceptional thermal conductor for heat dissipation while maintaining rigidity and resilience when used for EMI/RFI shielding in the telecom and electronics industries. Because of its superior performance, aluminum die casting provides several advantages over alternative processes and materials including:

    • Lightweight
    • High dimensional stability
    • Corrosion resistance
    • Excellent mechanical properties
    • Superior EMI and RFI shielding properties
    • High thermal and electrical conductivity
    • High Strength-to-weight ratio
    • A variety of decorative and protective finishes
    • Made from 100% recycled material and fully recyclable


  • +Major Alloy Characteristics

    Alloy 3: (ZAMAK 3, ZP3, ZL3, ZP0400, ZnAl4, ZDC2)
    Alloy 3 is the most widely used zinc alloy in North America. Its popularity is due to an excellent balance of desirable physical and mechanical properties, superb castability and long-term dimensional stability. No. 3 also offers excellent finishing characteristics for plating, painting and chromate treatments. It is the “standard” by which other zinc alloys are rated in terms of die casting.

    Alloy 5: (ZAMAK 5, ZP5, ZL5, ZP0410, ZnAl4Cu1, ZDC1)
    Alloy 5 is the most widely used zinc alloy in Europe. No. 5 has excellent castability characteristics and improved creep performance over No. 3. No. 5 castings are also marginally stronger and harder than No. 3, however, these improvements are accompanied by a reduction in ductility that can affect formability during secondary bending, riveting, swaging or crimping operations. No. 5 contains an addition of 1% copper which accounts for these property changes. When an extra measure of tensile performance is needed, No. 5 castings are recommended. The alloy is readily plated, finished and machined, comparable to No. 3 alloy.

    Alloy 7: (ZAMAK 7, ZL7)
    Alloy 7 is a modification of No 3 with a lower magnesium content and tighter impurities specification. This results in improved casting fluidity, ductility and surface finish, making the alloy popular where the die caster is making thin walled components requiring a good surface finish. However, several new high fluidity alloys have recently been developed with superior thin wall characteristics (see high fluidity alloy).

    Alloy 2: (ZAMAK 2, ZP2, ZL2, ZP0430, ZnAl4Cu3, Kirksite)
    Alloy 2 offers the highest strength and hardness of the conventional zinc alloys. The high copper content (3%) in No. 2 results in property changes upon long-term aging. These changes include slight dimensional growth, lower elongation and reduced impact performance (to levels similar to aluminum alloys) for die cast products. No. 2 alloy exhibits excellent castability and maintains higher strength and hardness levels after long term aging. No. 2 alloy is a good bearing material, and may eliminate bushings and wear inserts in die cast designs

    ZA-8: (ZP8)
    A good gravity casting alloy, ZA-8 can also be hot chamber die cast and is readily plated and finished using standard procedures for conventional zinc alloys. When the performance of Alloys No. 3 or No. 5 is in question, ZA-8 is often the die casting choice because of high strength and creep properties and efficient hot chamber castability.

    ZA-12 is the best gravity casting alloy for sand, permanent mold and the graphite mold casting process. It is also a good (cold chamber) die casting alloy. ZA-12 often competes with ZA-27 for strength applications. An excellent bearing alloy, ZA-12 is also platable, although plating adhesion is reduced compared to the conventional zinc alloys.

    ZA-27: (ZP27)
    This is an exceptionally strong alloy with a reported yield strength of 380 MPa (55ksi). It is light, and has excellent bearing and wear performance. Like ZA-12, this is a cold chamber die casting alloy and additional care is needed to ensure a sound casting. ZA-27 is not recommended for plating. When brute strength or wear resistance properties are needed, ZA-27 has demonstrated excellent performance.

    ACuZinc5:
    Developed by General Motors, this alloy has improved tensile strength, hardness and creep performance compared to the conventional zinc alloys. ACuZinc5’s strength and hardness properties are comparable to ZA-12. Testing has also shown ACuZinc5 to have excellent wear characteristics. Although this alloy is a hot chamber die casting alloy, it is more difficult to die cast with a higher wear rate of the shot end components in the die casting machine.
  • +Disadvantages of die casting

    Advantages of Die casting: Very high rate of production is achieved.Close dimensional tolerances of+ 0.025 mm is possible.Surface finish of o.8 microns can be obtained.Very thin sections of o.5o mm can be cast.Longer die-life is obtained.Less floor space is required.Unit cost is minimu.Only economical for nonferrous alloys. Not economical for small runs. Heavy castings cannot be cast. Cost of die and die casting equipment is high. Die casting usually contain some porosity due to the entrapped air.
  • +Types of dies used in die casting

    1. Single cavity Die: The single cavity die mainly used to produce one component at time of casting.

    2. Multiple cavity Die:It is used to produce a number of identical parts at one time.

    3. Unit Die:Unit die is used to produce different parts at one time.Unit Die

    4. Combination Die: It is used to produce several different parts for an assembly.Die Caster Owned

  • +Cold chamber die casting

    In cold chamber die casting the horizontal plunger is driven by air or hydraulic pressure to force the molten metal into the die.After pouring molten metal by ladle into the cylinder, the plunger will move inside and forces the molten metal into the cavity.After the metal solidified, the core is removed and then the die is opened.Ejectors are provided to remove the casting automatically from the die.Pressure loosely in cold chamber machine range from 300 to 16oo kg/ c㎡.
  • +Hot chamber die casting

    In hot chamber die casting the plunger operates in one end of gooseneck which is submerged in molten metal. Therefore molten metal flow by gravity into the cylinder by help of intake port, after applying force on plunger, the molten metal is forced into the die through the gooseneck channel and in gate. The force on plunger may be manually, mechanically or hydraulically. And at bottom one burner is provided for continuous heating throughout the operation to keep the metal in liquid form. Here the air pressure is below 15o kg/ c㎡

  • +What is Die Casting?

    Die casting is the art of rapidly and accurately dimensioned parts producing by the forcing molten metal under pressure into split metal dies which resemble a common type of permanent mould.

    Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts.

    It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished product. The term, “die casting,” is also used to describe the finished part.

    This process is particularly suitable for lead , magnesium ,tin , zinc alloy , copperandaluminium metals.

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