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Welcome to

KENWALT DIE CASTING COMPANY

Since 1968

 

Aluminum Die Casting          Zinc Die Casting


1-800-KENWALT

KenWalt Die Casting Company is an American Manufacturer and job shop foundry in the USA specializing in producing high quality Aluminum Alloy Die Casting and Zinc Alloy Die-Casting using a unique Vacuum Die Casting Process. The die casting process is commonly known by words or phrases such as Aluminum Die Casting, Zinc Die Casting, Aluminium, Zinc, Casting, Castings, Manufacturers, Zink, Foundry, Alloys, Diecast, Casting Process, Foundries, Zinc Alloy, Aluminium Alloys, Aluminum Alloys, Zinc Alloys, Die-casting, Metal Casting, Aluminum Casting, High Pressure Die Casting, Diecasting, Mold Casting, Pressure Casting, Zinc Casting, Foundry Casting, Die Casting Aluminum, Casting Zinc and Die Cast Parts.

american die casting companiesiso die casting companies  itar die casting companies 



HIGH PRESSURE DIE CASTING PROCESS

TECHNICAL INFORMATION




1. Introduction to Die Casting
2. Die Casting Machines
3. Die Casting Process
4. Advantages of Die Casting
5. Die Casting vs. Other Processes
6. Choosing Die Casting Alloys
7. Die Casting Molds Design
8. Future of Die Casting
9. Glossary of Die Casting Words



1. Introduction to Die Casting

The Die Casting Process is a manufacturing process for producing engineered metal parts by injecting molten metal under high pressure into reusable hardened steel molds called dies. Each mold or die can be designed to produce simple or complex shaped parts with smooth or textured surfaces and with a high degree of accuracy and repeatability. Close tolerances, hardness, machinability and plateablity are only a few of the advantages of die cast parts.

The high-pressure die casting process is the fastest and most cost-effective manufacturing process available for producing precise, high-integrity, near net-shape non-ferrous metal parts with excellent surface finishes.

Die castings
are important products that range from very small cell phone parts, computer parts and miniature die cast car parts to large and complex aircraft engine fuel valves, marine boat propellors, gas regulator valves and automotive parts such as transmission housings and wheel rims. 

Die castings
are among the largest volume, mass-produced items manufactured in the metalworking industry and can be found in thousands of consumer products and industries such as aerospace, automotive, commercial, computers, electronics, industrial, irrigation, lawn and garden, lighting, marine, medical, military, mining, railroad, transportation, etc.

Die cast parts are commonly found in many places around the home and office and are used for all types of parts such as bathroom fixtures, carburators, casings, covers, decorative hardward, die cast toys, door handles, faucets, flanges, grips, handles, heat sinks, housing, kitchen hardware, knobs, power tools, pumps, rotors, valves, plus many more. 


2. Die Casting Machines

Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die. Machine sizes range from 400 tons to 4000 tons. Regardless of their size, the only fundamental difference in die casting machines is the method used to inject molten metal into a die. The two methods are hot chamber for Zinc alloys and cold chamber for Aluminum alloys.


3. Die Casting Process

In the Aluminum die casting process, solid ingots of aluminum are melted in furnaces at approximately 1200-1300 Degrees Fahrenheit. Once liquified, the aluminum metal is picked up using a ladle and poured by hand or robotically into a steel shot sleeve. The two halves of the die or mold are mounted on the machine and the machine closed and holds the two die halves together. The molten aluminum metal is then injected with hydraulic pressure into the two halves of the die. The molten aluminum metal is then held under high pressure until the metal solidifies, usualy within only a matter of 2-15 seconds depending on the size of the parts. The die halves are then opened and the part(s) ejected and removed by hand or robotically. Finishing operations follow such as trimming, tumble deburring, precision machining, painting, anodizing, chrome plating and assembly.

In the Zinc die casting process, ingots of zinc are melted in a furnace at approximately 700-800 Degrees Fahrenheit. Once liquified, the zinc metal remains in the furnace. The shot sleeve (called a gooseneck for its shape like a goose's neck) is immersed in the furnace and the zinc metal is injected directly from the furnace into the two die halves held together by the machine. The remaining process is identical to that of casting aluminum parts.

A complete die casting cycle can vary from seconds for small components weighing less than an ounce to three minutes for a casting weighing several pounds.


4. Advantages of Die Casting

Die casting is an efficient and very cost-effective manufacturing process that offers a broader range of shapes, sizes and dimensionally precise die castings than any other manufacturing process. Parts have a long lifespan and designers can gain a number of advantages and benefits by specifying die cast parts.

High-speed production
- Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.

Dimensional accuracy and stability
- Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.

Strength and weight
- Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.

Multiple finishing techniques
- Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.

Simplified Assembly - Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes, or external threads can be cast.


5. Die Casting vs. Other Processes

Die Casting vs. Plastic Injection Molding
- Die casting produces stronger parts with closer tolerances that have greater stability and durability. Die cast parts are more heat resistant, have greater resistance to temperature extremes and superior electrical properties. Die castings are far superior to plastics for applications such as anodizing or chrome plating. Die castings  Die castings are much better for permanence under loads and resistance to chemicals and ultra-violent rays.

Die Casting vs. Sand Casting
- Die casting is faster and produces parts that cost much less, have closer dimensional limits, thinner casting walls and much smoother surfaces. Die cast parts require much less machining, finishing costs are less and tooling can last for 20 years or more and make thousands and even millions of parts with proper maintenance.

Die Casting vs. Permanent Mold
- Die casting offers many of the same advantages as compared with sand casting. Faster production, much lower costs, closer dimensional limits, thinner casting wall sections, holes cored to near net shape, lower machining and finishing costs and extended tooling life.

Die Casting vs. Forging
- Die casting produces complex shapes, cast-in cored holes, closer tolerances, thinner walls and lower finishing costs. Complex shapes and cast-in cored holes are not available with forging.

Die Casting vs. Stamping
- Die casting produces more complex shapes with variations in section thicknesses, closer dimensional tolerances and fewer assembly operations. One casting may replace several stampings and reduce assembly time.

Die Casting vs. Screw Machine Products
- Die casting produces shapes that are difficult or impossible to produce from bar or tubular stock, while maintaining tolerances without tooling adjustments. Die casting requires fewer operations and reduced waste and scrap.


6. Choosing Die Casting Alloys

Aluminum and Zinc metal alloys available for die casting offer distinct advantages depending upon the end use of the product:

Aluminum Die Casting Alloys
- These die casting alloys are lightweight and possess high dimensional stability allowing for complex shapes and thin walls. Aluminum has good corrosion resistance and mechanical properties, high thermal and electrical conductivity, as well as strength at high temperatures. Aluminum is the most common die cast alloy because of it's many beneficial properties.



Zinc Die Casting Alloys - The easiest alloy to cast, it offers high ductility, high impact strength and is easily plated. Zinc is economical for small parts, has a low melting point and promotes long die life.

Magnesium - The easiest alloy to machine, magnesium has an excellent strength-to-weight ratio and is the lightest alloy commonly die cast. However, magnesium is highly flammable and extremely hazardous to manufacture.

Copper - This alloy possesses high hardness, corrosion resistance and mechanical properties. It offers excellent wear resistance and dimensional stability with strength approaching that of steel parts. However, high metal temperatures lead to rapid die degradation and the added costs of new tooling.

Lead and Tin - These alloys offer high density and close dimensions and are also used for special forms of corrosion resistance. However, the toxicity of Lead based alloys makes Lead dangerous, unhealthy and costly.

CLICK HERE FOR MORE
ABOUT ZINC DIE CASTING ALLOYS



7. Die Casting Molds Design

Dies, or die casting molds, are made of alloy tool steels in at least two sections, the fixed die half, or cover half, and the ejector die half, to permit removal of castings. Modern dies also may have moveable slides, cores or other sections to produce holes, threads and other desired shapes in the casting. Sprue holes in the fixed die half allow molten metal to enter the die and fill the cavity. The ejector half usually contains the runners (passageways) and gates (inlets) that route molten metal to the cavity. Dies also include locking pins to secure the two halves, ejector pins to help remove the cast part, and openings for coolant and lubricant.

When the die casting machine closes, the two die halves are locked and held together by the machine’s hydraulic pressure. The surface where the ejector and fixed halves of the die meet and lock is referred to as the "die parting line." The total projected surface area of the part being cast, measured at the die parting line, and the pressure required of the machine to inject metal into the die cavity governs the clamping force of the machine.


8. Future of Die Casting

Improvements continue to be made in both the casting process and the alloys used in die casting that continue to expand die casting applications into almost every known market in the world. Today’s die casters can efficiently and economically produce strong, durable and dimensionally precise castings in a wide variety of shapes, sizes and wall thicknesses.

9. Glossary of Die Casting Words

Automation – Industry casting term commonly used to describe the mechanization of various aspects of the die casting process.

Biscuit – Excess of ladled metal remaining in the shot sleeve of a cold chamber die casting machine. It is part of the cast shot and is removed from the die with the casting.


Blister – A surface bubble caused by gas expansion (usually from heating) which was trapped within the die casting or beneath the plating.


Blow holes – Voids or pores which may occur due to entrapped gas or shrinkage during solidification, usually evident in heavy sections (see porosity).


Cavity – The recess or impressions in a die in which the casting is formed.


Cold chamber machine – A type of casting machine in which the metal injection mechanism is not submerged in molten metal.


Checking – Fine cracks on the surface of a die which produce corresponding raised veins on die castings. Caused by repeated heating of the die surface by injected molten alloys.


Creep – Plastic deformation of metals held for long periods at stresses lower than yield strength.


Die lubricant – Liquid formulations applied to the die to facilitate casting release and prevent soldering.


Dimensional stability – Ability of a component to retain its shape and size over a long period in service.


Dowel pin – A guide pin which assures registry between cavities in two die halves.


Draft – The taper given to walls, cores and other parts of the die cavity to permit easy ejection of the casting.


Ejector marks – Marks left on castings by ejector pins.


Ejector plate – A plate to which ejector pins are attached and which actuates them.


Fillet – Curved junction of two surfaces, e.g., walls which would meet at a sharp angle.


Flash – A thin web or fin of metal on a casting which occurs at die partings, vents and around moveable cores. This excess metal is due to working and operating clearances in a die.


Gate – Passage for molten metal which connects runner with die cavity. Also, the entire ejected content of a die, including castings, gates, runners, sprue (or biscuit) and flash.


Gooseneck – Spout connecting a metal pot or chamber with a nozzle or sprue hole in the die and containing a passage through which molten metal is forced on its way to the die. It is the metal injection mechanism in a hot chamber type of die casting machine.


Growth – Expansion of a casting as a result of aging or of intergranular corrosion, or both.


Heat checking – (See checking)


Hot chamber machines – Die casting machines which have the plunger, gooseneck (metal pressure chamber) immersed in molten metal in the holding furnace.


Hot short – Term used to describe an alloy which is brittle or lacks strength at elevated temperatures.


Impact strength – Ability to resist shock, as measured by a suitable testing machine.


Impression – Cavity in a die. Also, the mark or recess left by a ball, or penetrator of a hardness tester.


Ingot – Metal or alloy cast in a convenient shape for storage, shipping and remelting.


Injection – The process of forcing molten metal into a die.


Insert – A piece of material, usually metal, which is placed in a die before each shot. When molten metal is cast around it, it becomes an integral part of the die casting.


Intergranular corrosion – A type of corrosion which preferentially attacks grain boundaries of metals or alloys, resulting in deep penetration.


Loose piece, knockout – A type of core (which forms undercuts) which is positioned in, but not fastened to a die. It is so arranged as to be ejected with the casting and from which it is removed. It is used repeatedly for the same purpose.


Metal saver – Core used primarily to reduce amount of metal in a casting and to avoid sections of excessive thickness.


Multiple cavity die – A die having more than one duplicate impression.


Nozzle – Outlet end of a gooseneck or the tubular fitting which joins the gooseneck to the sprue hole.


Overflows – Recesses in a die located around the perimeter of a casting to trap excess  metal, including impurities, and assist complete fill and venting of air.


Parting line – A mark left on a die casting where the die halves meet; also, the mating surface of the cover and ejector portions of the die.


Plunger – Ram or piston which forces molten metal into a die.


Port – Opening through which molten metal enters the injection cylinder.


Porosity – Voids resulting from trapped air, gas or shrinkage during solidification. Click Here for more about Porosity in Castings.

Process control – Where parameters of a process are studied and correctly applied in the manufacturing process to produce high quality parts.


Runner – Die passage connecting sprue or plunger holes of a die to the gate where molten metal enters the cavity or cavities.


Shot – That segment of the casting cycle in which molten metal is forced into the die.

Shrinkage, solidification – Dimensional reduction that accompanies the freezing (solidification) of metal passing from the molten to the solid state.

Shrink mark – A surface depression which sometimes occurs next to a heavy section that cools more slowly than adjacent areas.


Slide – The portion of the die arranged to move parallel to die parting. The inner end forms a part of the die cavity wall that involves one or more undercuts and sometimes includes a core or cores.


Soldering – Adherence of molten metal to portions of the die.


Split gate – A gate of castings having the sprue or plunger axis in the die parting.


Sprue – Metal that fills the conical passage (sprue hole) which connects the nozzle with runners.


Sprue pin
– A tapered pin with rounded end projecting into a sprue hole and acting as a core which deflects metal and aids in the removal of the sprue.


Toggle – Linkage employed to mechanically multiply pressure when locking the dies of a casting machine.


Trim die – A die for shearing or shaving flash from a die casting.


Unit die – A die interchangeable with others in a common holder.


Undercut – Recess in the side wall or cored hole of a casting disposed so that a slide or special form of core (such as a knockout) is required to permit ejection of the casting from the die.


Vent – Narrow passage, usually wide and thin, at the die parting which permits air to escape from the die cavity as it is filled with molten metal. Usually attached to overflows.


Void – A large pore or hole within the wall of a casting usually caused by entrapped gas. A blow hole.


Waterline – A tube or passage through which water is circulated to cool a casting die.







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MANUFACTURING

San Fernando Valley Business Journal Manufacturing

KenWalt Die Casting is honored to have received the prestigeous Manufacturing Leadership Award for being one of the Top 20 Manufacturers from the San Fernando Valley Business Journal as well as receiving a Certificate of Recognition from the State of California Assembly as one of the Region's Top Manufacturing Companies and in addition for being spotlighted in the newspaper's Current Edition Top Story Special Report on Manufacturing:

Solar Powered Die Casting Foundry

"KenWalt Die Casting, a very traditional industry, is using solar energy (alternative energy) to help power its facility in Sun Valley into the future."



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1ST
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in USA to GO SOLAR*

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KenWalt Die Casting Expands "Green" Facilities With Recycling and 'Solar Power'

Sun Valley, CA USA

In line with our continuing commitment to make a positive impact in society and improve lives and our environment, KenWalt Die Casting Company is expanding upon it's 'Commitment to Excellence' by further reducing our environmental impact in our newly expanded offices, secondary facilities, new inventory facility and our Aluminum and Zinc Die Casting production facility.

 

"Energy conservation and recycling raw materials are two key factors in our energy conservation efforts to enhance our activities and improve lives and our environment. By recycling and reusing 100% of our aluminum and zinc alloy materials as well as pallets, packaging containers, filters and hydraulic oil used in our aluminum and zinc die casting process, we are making a big difference", says KenWalt's Quality Manager and Co-Owner Kenny Zaucha.

 

For years KenWalt has continued to implement energy conservation actions to conserve materials and energy, such as using energy efficient furnaces to melt aluminum and zinc alloys and reusing machine lubrication oils and die sprays. From turning off little used lights to early work schedules that avoid peek energy usage, KenWalt's employees, both individually and as a team, contribute to energy conservation and improving our environment.

 

KenWalt Die Casting Company installed a brand NEW 35.9 kW SOLAR SYSTEM thanks to the cooperation and efforts of SolarCity Corporation (SOLARCITY), Los Angeles Department of Building & Safety (LADBS), Los Angeles Department of Water and Power (LADWP), and US  Government Tax Credit Incentives. Our new clean and renewable solar energy system will lower our aluminum and zinc die casting operating costs, enable us to remain competitive both nationally and internationally, continue expanding and creating more US jobs and enable us pass on those cost savings to our customers.

*1st of 395 Aluminum Die Casting Companies in the USA to go Solar based on preliminary research


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KenWalt Die Casting Supplies China With Die
Castings Made in USA!

KenWalt Die Casting ships high quality, low cost die castings overseas to our customer in China!

Another example of how KenWalt Die Casting Company's knowledge, professionalism and experience produces cost savings and success for our customers in the USA and Overseas!


Hidden Costs of
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Die Casting Companies Ask KenWalt for Help!

An example of what another die casting company had to say about us:

" Thank you so much for the sample parts..We hope the anodizing outcome will help our customer."

(One month later) "Just to let you know that the parts anodized beautifully. They (our customer) were happy with the results and we were awarded the contract.
I hope we are in a position to be as helpful as you folks were in getting this job. It's nice to know there are a few of us who work together left out there."
D.S.

What some of our satisfied customers had to say about us:

"For us to continue a commitment of 98% on-time delivery for our customers, we must first receive this expectation from our vendors. Your performance has been 100%! All items shipped on-time with 0 defects. Amazing."

F.G.

"Please thank all of your people for their efforts. The completed product delivered to us is beautiful. We foresee many more orders!"
D.U.

"We are very grateful for the informative discussion and tour of your die casting facility. We were genuinely impressed with your helpful attitude, knowledge of business and ability to explain the casting process. Now we feel confident that our companies are in good hands!"
A.E.

"Enclosed is a VCR tape we made of your casting in our x-ray machine. Porosity shows in these as white specs. As you can see from the tape, we couldn't find any in your product, so we have a winner here."
D.

"I received a letter from our customer that awarded us with a "Preferred Vendor Status". We met our delivery schedule and the product is performing as expected. That could not have happened without KenWalt...following through and making sure we met our delivery schedules. Thanks, I've been asked to bid on the next contract."

K.R.


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KenWalt Die Casting Company

Aluminum Die Casting Parts Company | Zinc Die Casting Parts Company
Aluminum Die Castings | Zinc Die Castings

8719 Bradley Ave Sun Valley, California 91352
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