High Pressure vs Low Pressure Aluminum Die Casting
Pressure Die Casting is a manufacturing process that is done by applying external pressure during casting. Depending on the extent of pressure applied, it can be categorized into two types. They are,
- High Pressure Die Casting (HPDC)
- Low Pressure Die Casting (LPDC)
This article discussed the key points of High-Pressure Aluminum Die Casting and Low-Pressure Aluminum Die Casting.
High Pressure Aluminum Die Casting
HPDC is the most commonly used manufacturing process all over the world. Currently, about 70% of die casting manufacturers use the high pressure aluminum die casting process.
We have described the process of aluminum high pressure die casting below:
- The aluminum alloys are melted in a furnace that is separate from the die casting equipment.
- Then carry the molten aluminum into the equipment’s shot sleeve using a manual or robot arm-operated ladle.
- Next, the piston will push the molten metal with high pressure to fill the mold. Now, leave the casting inside the dies for a specified period to cool down and solidify.
- Finally, separate the die halves, and retrieve the completed casting.
Low Pressure Die Casting
The low pressure aluminum casting machine’s structure has some significant differences compared to high pressure aluminum casting equipment.
We have described the process of aluminium low pressure die casting below:
- The aluminum alloy is melted in a sealed furnace. The die halves are positioned on top of the furnace and connected using a riser tube.
- Apply low air pressure from within the furnace. It will cause the molten aluminum to rise through the tube and fill up the die cavity.
- Maintain the air pressure until the casting has solidified.
- Finally, open the dies and retrieve the casting.
Need a High Pressure Aluminum Die Casting Manufacturer in China?
Our services include,
- Rapid Prototyping
- Aluminum Die Casting Tooling
- Aluminum Die Casting Manufacturing
- CNC Machining
- Surface Finishing
As you can see, we are capable of design to the finishing of a die casting project. Our vast manufacturing capabilities enable us to ensure consistent quality for our services.
Below are some aspects that support our core competencies.
First-Class Production Facility
Sunrise Metal has two die casting facilities, one tooling and one prototyping shop in Kunshan and Nantong. Our factories are enriched first-class manufacturing equipment from renowned brands. Therefore, you can rest assured about our capabilities.
We have a long-standing history in the die casting business. Therefore, we have experienced professionals within the organization who knows what they are doing. So, our engineers can provide turn-key solutions, and quality control experts can ensure consistency for every part.
Our manufacturing facility and processes are verified and certified by international standards like ISO 9001 and IATF 16949. The certifications complement our quality control standards and facilities for aluminum die casting production.
Which Pressure Die Casting Process Do You Use?
Sunrise Metal uses the high-pressure die casting process for manufacturing. We prefer this method to ensure maximum economy and production capacity. Moreover, we provide turn-key solutions for every project to achieve maximum efficiency.
Our unique production techniques allow us to overcome the common issues faced during high pressure aluminum casting.
When Should I Choose the HPDC Process?
There are two types of equipment for high pressure die casting. Namely, the cold chamber and hot chamber die casting equipment. You need to use the cold chamber machines for high pressure aluminum casting.
Choose High Pressure Die Casting (HPDC) process when you have a high production demand. HPDC is one of the fastest and cost-effective manufacturing techniques. With this process, you can cast non-ferrous metals more conveniently.
Therefore, suppliers are able to keep up with high production demands regardless of the part’s complexity. It is easier to create thin-walled parts using the HPDC process. Moreover, you get better surface finish quality using this process.
But, high pressure die casting has increased the potential to create porosity inside a casting. It compromises the structural integrity and makes it unsuitable for heat treatment.
When Should I Choose LPDC Process?
Choose Low Pressure Die Casting (LPDC) process when you have to diecast large parts and have a high-quality requirement. Low pressure die casting equipment doesn’t limit you to a specific size. You can cast very large parts in this process.
Low pressure aluminum die casting induces minimum turbulence during casting. Therefore, the casting has little to no porosity. Thus, the casting has high structural integrity with excellent mechanical properties.
However, the casting cycles are significantly slower than HPDC. So, this will increase the production time. Moreover, you can’t die cast intricate thin-walled parts properly.
How to Minimize the Die Casting Defects in HPDC?
Several factors can induce porosity and other forms of defect during aluminum high pressure die casting. You can reduce the defects by improving the part design according to some guidelines. We have discussed some of the most common types of defects below.
Porosity is a common issue you will face during the HPDC process. It is really difficult to get rid of porosity completely. But, you can virtually eliminate porosity by installing a vacuum into the equipment.
Flash is also a common phenomenon in high pressure aluminum casting. It is the excess material that leaks along the parting lines. Flash is usually formed when the injection pressure exceeds the clamping force. You can eliminate flash defects by using die casting equipment of sufficient tonnage.
Non-uniform cooling may cause tearing in hot spots of your parts. Non-uniform cooling usually takes place due to variation of wall thickness in a casting. The designer can deal with this issue by improving the design.
Unfilled sections may exist in the die cavity due to multiple reasons. You can avoid this issue by monitoring the shot volume, speed, and pouring temperature.