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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 asAluminum
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.
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 asbathroom 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.
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.
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."
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 TESLAA Corporation (TESLA), 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
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!
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."
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
Toll
Free:
1-800-KENWALT (1-800-536-9258)
Ph:
1-818-768-5800
Fax 1-818-768-0854 Click Here to Send Us an
E-mail
