Delivering Quality as a Leading Aluminum Die Casting Manufacturer in China

SUNRISE METAL-PRESSURE DIE CASTING MANUFACTURER

This article is a complete Frequently Asked Questions (FAQ) guide for pressure die castings manufacturers. The goal of this guide is to provide you with answers to all the questions you have about pressure die casting manufacturers. It will guide you to make the best decision in choosing a reliable manufacturer for the success of your business.

What Is Pressure Die Casting?

Pressure die casting is a manufacturing process whereby a metal is melted and pumped into a die under high pressure. Then the metal takes the shape of the die upon cooling.

The melted metal fills very small cavities or spaces of the die. This makes it possible for parts of smaller thicknesses or sizes to be molded. In general, high-pressure casting is suitable for molding parts that are less thick and have a smaller size. Below are some advantages of pressure die casting:

• High-pressure die casting ensures accuracy and precision in the manufacturing of parts or equipment.
• Pressure die casting is a cost-effective and highly efficient production process in the industrial sector.
• It also enables higher volumes of production to take place within a short time using the same mold or cast.

What Does Pressure Die Casting Manufacturer Mean?

Pressure die casting manufacturer is a company that uses pressure die casting machines and processes to produce parts, equipment, or tools.

China has some of the world’s leading pressure die casting manufacturers that produce high-quality products for different markets.

Sunrise Metal is your No.1 pressure die casting manufacturer in China and you can trust us with all your die cast needs.

What Are The Types Of Die Castings Used By Pressure Die Cast Manufacturers?

There are two basic types of pressure die castings that manufacturers use. It is important to note that there are other die casting types for different purposes.

Most manufacturers in China and the world at large use the hot chamber and cold chamber pressure die casting.

Hot Chamber Die Casting

The hot chamber pressure die casting is for metals such as zinc, lead, and copper alloys that have low melting points and high fluidity.

The cylinder of the injector is dipped into the melted metal. The plunger then pushes the metal with pressure into the die. The metal fills the die and takes its shape when it solidifies.

The advantage of this process is that it minimizes the possibility or risk of air getting in touch with the metal.

The disadvantage however is that the rate of corrosion increases.

Cold Chamber Die Casting

The cold chamber pressure die casting is suitable for metals such as aluminum and magnesium which has high melting points.

In this process, the aluminum or magnesium melted metal is introduced into a cold chamber. The metal is then pushed into the mold by a hydraulic plunger and takes the shape of the mold after it solidifies.

Sunrise Metals is your reliable manufacturer in China to provide your company with the best pressure die castings solutions.

How Does Pressure Die Casting Manufacturers Die Cast Aluminum?

Aluminum die casting uses the cold chamber method of casting due to its high melting temperature.

The heating component of the cold chamber die casting method is separated from the die casting machine.

The aluminum metal is put into a holding or melting container. The holding container is placed on a furnace. The aluminum metal is then heated at a higher temperature until it becomes liquid.

A ladle is used to fetch the aluminum liquid and then poured into the chamber of the die casting machine.

The aluminum liquid is then pumped at high pressure into a mold cavity or die using a hydraulic press system.

The aluminum fills all the mold cavity at a higher pressure. The aluminum in the mold cavity is allowed to cool and become solid. It takes the shape of the mold cavity when it becomes solid.

When the aluminum liquid becomes solid, the die chamber is opened. The solid aluminum is taken out of the die chamber using an ejector.

The solidified aluminum is then sawed to take away unwanted parts. This is because some parts of the die get attached to the aluminum in the process of solidification.

When the aluminum cast is trimmed, it is polished. Some finishing work is also done on the aluminum.

The aluminum cast goes through various degrees of test and inspection to ensure it has no defects. This is also to make sure it meets the desired quality standards.

As the leading pressure casting manufacturer in China, Sunrise has well-equipped laboratories and machines. This helps us to conduct all the relevant tests to ensure our products meet the highest quality standards.

your company can count on us for all your aluminum cast product needs.

What Are The Advantages Of Die Casting To Manufacturers And Their Clients?

Most manufacturers in China and the world at large use die casting for production for a number of good reasons.

First of all, die casting is chosen over other manufacturing processes because it has a high degree of accuracy. Equipment of very complex shapes can be produced by die casting.

The die casting process can be repeated and automated.  Large volumes of products can be obtained within a short time.

Waste is reduced during die casting manufacturing. Die cast products have better product life. There is the stability of tools.

What Materials Are Used By High-Pressure Die Casting Manufacturers?

The materials used for die casting are mostly nonferrous metals. Nonferrous metals are metals with little or no amount of iron.

These include zinc, magnesium, lead, aluminum, pewter, tin, etc.

Aluminum alloy is the most widely used material in die casting. Pressure die casting manufacturers choose aluminum over other materials because it possesses some unique properties and properties.

Aluminum is strong, hard, and light. Aluminum’s strength and hardness increase the lifetime of aluminum die cast products. Its light nature makes it a favorable material for manufacturing lightweight parts or products.

Aluminum is a good conductor of electricity and heat. It is flexible and can be easily molded into different shapes. It is resistant to corrosion and gives cast products an excellent finish.

The most common aluminum alloys used by pressure die casting manufacturers are A380,383, Alsi12, Alsi9CU. A380 is the most commonly used aluminum alloy and considered to be the best among the rest.

What Is The Difference Between Cast Aluminum And Die Cast Aluminum?

Cast aluminum and die-cast aluminum are not the same. For you to understand the difference between the two, we will explain both of them.

Cast Aluminum

In cast aluminum, the aluminum metal is heated using a furnace. It is then poured into a mold and allowed to cool on its own. When it cools, it takes the shape of the mold.

Cast aluminum is used for manufacturing aluminum products on a smaller scale. It does not involve any industrial process.

Die-Cast Aluminum

Unlike cast aluminum, die-cast aluminum is an industrial method of producing aluminum products.

The aluminum metal is melted and injected into a mold or die by applying high pressure to it. Because of the high pressure involved, the melted aluminum is able to fill all the cavities of the mold.

Through this manufacturing process, high precision and complex products are been produced.

High volume production is achieved within a short time through this process.

Die cast aluminum products are stronger than that of cast aluminum. This is because the aluminum is injected into the mold and not poured.

What Are The Major Testing Tools Used By Pressure Die Casting Manufacturers?

As a leading pressure die cast manufacturer in China, we have quality and customer satisfaction as our main goals.

Sunrise has a premium laboratory facility equipped with standard testing instruments, which helps us to achieve these goals.

Some of the equipment at our laboratory are:

X-ray detector, Coordinate Measuring Machine, Caliper, and many more.

These testing equipment helps us to conduct accurate and precise measurements on all materials and products. We are able to detect any abnormality in the production process with this equipment and rectify them.

This helps us to supply businesses with highly accurate products. Your company can also join our numerous happy clients around the world by getting highly reliable products from us.

What Is The Difference Between Gravity Die Casting And Pressure Die Casting Manufacturing?

Die casting is basically categorized into 3 different forms. They are:

• High pressure
• low pressure
• gravity casting.

The three forms of die casting involve introducing melted metal into a mold to produce equipment or material of specific shape.

They all use non-ferrous metals like aluminum, magnesium, lead, zinc, etc.

The major difference between pressure and gravity die casting is the way the metal is introduced into the mold.

In gravity sand casting, the metal is poured into the mold from the top of the vessel containing the mold. This ensures the mold is filled bottom-up by the force of gravity.

Gravity die casting is used for the production of less complex products. It is also suitable for products with a bigger thickness.

In pressure die casting, the metal is introduced into a mold with pressure. The pressure ranges from 1500-24500 psi.

Due to the high pressure in this type of casting, it is suitable for complex and less thick products or materials. The high pressure forces the molten metal into the cavities of the mold with speed.

What Is The Importance Of Advanced Equipment  In Die Casting Manufacturing?

Advanced equipment increases efficiency in die casting manufacturing.

One of our goals as China’s leading die casting manufacturer is to deliver our core services to our clients in an efficient manner.

When we talk about efficiency, one key element or indicator is the time used for manufacturing.

Sunrise Metal’s goal is to produce higher volumes of quality products for our clients at a faster rate without wasting resources. This helps us to meet the demands of our clients anytime they make an order for products.

Advanced equipment helps us to achieve this goal because we have highly advanced machines and systems that help us to produce more goods within a short time.

And also our employees are equipped with highly advanced equipment and tools, they are able to work with ease without wasting time and raw materials.

The availability of highly advanced machines and systems also ensures accuracy and precision during die cast manufacturing. This helps to reduce wastage of raw materials, thereby increasing cost-effectiveness for manufacturing.

What Are Aluminum Die Casting Products?

Aluminum die casting products are aluminum equipment, machine parts, tools, materials or any product manufactured by die casting.

Different companies manufacture different aluminum die casting products, depending on the type of markets they serve. It could be a door handle, key, cell phone frame, etc.

As China’s leading die-cast manufacturer, we serve our global clients with a lot of aluminum die casting products.

Below are some of our products for the different industries mentioned above:

Medical

Telecommunication

Automotive

Marine

What Makes Aluminum Die Cast Manufacturers Reliable?

As a company that wants to succeed in your industry, you need to partner with a reliable pressure die, cast manufacturer.

A reliable pressure die casting manufacturer is the one that you can trust to deliver quality products on time.

The following are some of the important factors you need to look for in a reliable pressure die, casting manufacturer.

Quality of pressure die casting products.

A reliable manufacturer should have quality control systems to ensure its products meet the International recommended standard.

Such a manufacturer needs to have quality manufacturing processes and standard machines to help it supply you with high-quality goods.

Sunrise Metals is China’s No.1 manufacturer of pressure die casting products.

We operate by following the highest manufacturing standards that help us to produce quality die cast products for our clients worldwide. We have invested in a premium laboratory facility that helps us to test all our materials and products during manufacturing.

We can help your company with all your die casting needs. You can trust us for the manufacturing of quality pressure die cast products that will deliver your desired results.

Experience of the Manufacturer

A reliable pressure die cast manufacturer has experience in its market niche.

This means they have experienced engineering team and workers who are able to produce excellent products for your business.

Sunrise metals have been in operation for over 10 years in the die cast manufacturing industry. We boast of a very experienced engineering team and workers who understand this industry. *  Our engineering manager has 23 years’ experience in the die cast manufacturing industry. This pool of experience from our expert engineers and workers makes us reliable to serve your company with the best die cast products.

Production capability of the Manufacturer

A reliable manufacturer should be able to meet the production demands of your business at any time.

You need to know how many products the manufacturer can produce in a day. This will help you to know if they can meet your product demand.

As the leading pressure die casting manufacturer in China, we have the best machines and an experienced workforce. This together with our highly experienced workforce and efficient manufacturing systems helps us to produce high volumes of products daily.

Your company can trust us, China’s leading die cast manufacturer to meet all your product demands.

Ability To Deliver Die Casting Products on Time.

The next factor that makes a pressure die cast manufacturer reliable is its ability to deliver your products on time.

This factor has a direct relationship with the production capability of the company.

Sunrise metals have very efficient systems in place that guarantee the fast delivery of products to our clients worldwide.

This makes it possible to always receive your products on time so that you won’t miss valuable business opportunities.

Cost-effectiveness

Another quality of a reliable manufacturer is their ability to sell their products at reasonable cheaper prices to their clients.

The success and profitability of our clients is our priority. We don’t only give our clients quality die cast products, we also make sure they get our products at a cheaper price.

Businesses who want to buy any of our die cast products can negotiate with us on our prices. This helps our clients to get our products at a cheaper price that makes them profitable.

Market niche.

You need to select a manufacturer that is in the same market niche as you. This is because companies have different niches they specialize in.

A manufacturer in your niche market understands your industry or business well. They also understand the performance requirements and challenges in your industry.

This helps them to manufacture products that suit your industry or market in order to get the results you desire.

As China’s No.1 manufacturer of pressure die cast products, we have products that serve many markets. This helps us to reach a lot of companies and businesses in the world.

What Measures Are Taken By Pressure Die Casting Manufacturers To Ensure They Produce High-Quality Goods?

In order to produce high-quality products, pressure die cast manufacturers should:

• continuously improve their production processes and operations
• conduct regular checks and test to eliminate product defects
• follow the recommended International standards.
• avoid producing non-conforming products
• train their staff to work efficiently
• aim to improve their production efficiency

Sunrise metal’s priority is to serve our clients with quality products and to make them satisfied at all times.

We strive every day to achieve the highest level of customer satisfaction. We diligently follow approved international standards in all our operations. We also make sure all regulatory requirements are met.

We have a well-equipped laboratory which helps us to test and carry out accurate measurements on all our products during and after production. This helps us to see and correct any defects ahead of time, making all our products in the market of extreme quality.

What Markets DO Pressure Die Casting Manufacturers Like Sunrise Metal Provide Services For?

Pressure die casting manufacturers serve a wide range of markets. Die casting markets are categorized into four (4) main sections. It is categorized by the type of process, the type of application, the type of raw material, and geography.

Under the type of process market, we have die cast products made using different types of die casting process like pressure die casting, vacuum die casting, gravity die casting, etc.

Under markets by application, we have automotive, medical, electrical, telecom, marine, etc.

Die cast market categorized by raw materials focus on the type of raw material used for manufacturing a product.

The die casting market under geography considers specific countries or continents of the world like Europe, North America, Asia, etc. where there is a demand for die casting products.

What Machines Are Used Pressure Die Casting Manufacturers?

There are two types of machines that are used in high-pressure casting manufacturing. They are cold chamber casting machines and hot-chamber casting machine.

Cold Chamber Casting Machine

The cold chamber pressure casting machine is used for casting metals with high melting temperatures like Aluminum.

The cold chamber pressure casting machine has the following components:

• Cold chamber where the melted metal is poured into the Hydraulic system with a cylinder and a piston. This pushes the molten metal into the mold cavity.
• Mold cavity that is made of steel. The melted metal takes the shape of the mold cavity after it’s been introduced into it.
• Ejector that is operated to eject or remove the die cast or solidified metal.

How it operates

• The melted metal is poured into the cold chamber. The mold or die at this stage is closed
• The plunger in the cold chamber pushes the metal into the mold cavity under high pressure. The mold is opened during this process. The metal is held in position by the piston until it becomes solid.
• The mold cavity opens. The plunger further pushes forward to keep the cast metal in the ejector die.
• The ejector opens and the cast metal is released. The piston withdraws back to its original position.

Hot Chamber Casting Machine

The hot chamber pressure casting is used for casting metals with low melting temperatures.  The hot chamber casting machine has a melting container connected to it. The metal is put into the melting container and placed on a furnace for it to melt into liquid.

How it operates

The injection system is lowered into the melted metal. The plunger pushes the melted metal into the die through a feeding system connected to the metal container.  The melted metal is held in position by the plunger until it solidifies. The ejector is operated to release the die cast metal.

Why Do Manufacturers Choose Die Casting Over Other Casting Methods?

Die casting manufacturers choose die casting over other casting methods because of a number of good reasons.

Let’s take the manufacturing of gears as an example.  Gears are very complex in nature and have complex internal structures. It is very difficult to manufacture gears and other complex equipment with other casting methods.

This is where pressure die casting comes in. With pressure die casting, almost any complex machine part or equipment can be manufactured easily with speed, accuracy, and precision.

In summary, die casting is the most preferred manufacturing process because of the following reasons:

• Mass production is made possible through die casting. High volumes of die cast products can be produced within a short time.
• Very complex equipment can be produced through die casting.
• Die casting ensures a high degree of precision and accuracy.
• It can be repeated and automated.
• Die casting results in better product life.
• Die casting reduces scrap or waste during production
• There is the stability of tools during die casting.

As China’s leading die casting manufacturer, Sunrise Metal has mastered the art of die casting and we use it to produce value-added high-quality products for our clients globally.

We can meet all of your company’s die casting needs because of our perfection and experience in high pressure die casting.

What Major Tests Are Done By Pressure Die Casting Manufacturers During Production?

In order to ensure that quality goods are produced for clients, pressure die casting manufacturers conduct various tests during and after manufacturing.

As the leading and most reliable pressure die casting manufacturer in China, Sunrise metals conduct strict tests during production.

Our goal is to create value-added products for our clients worldwide and to offer them excellent services.

We have a well-equipped laboratory that has standard measuring instruments and machines that help us to conduct tests to eliminate all product defects.

Some of the tests we conduct during our manufacturing processes are the following:

Porosity test:  We use the X-Ray detector to test the porosity of parts and all work pieces.  This helps us to detect if there are any pores on parts or work pieces so that the correct action is taken to control it.

Cleanliness test:  We conduct a cleanliness test on all our work piece and products to make sure they are clean and suitable for our clients. This test is done with a cleanliness tester.  This test helps to reveal any potential impurities on manufactured parts.

Accuracy and Completeness test: We use the Zeiss Coordinate Measuring Machine (CMM) to test for accuracy and completeness of all manufactured parts and products.

Precision test: In order to produce quality goods that will be suitable and efficient for our clients, we conduct a precision test. The digital caliper is used to take precise measurements of manufactured parts and all products.

Corrosion resistance test:

This test is done on manufactured products to verify their ability to resist corrosion.  The salt sprayer tester is used for this test.

Thickness testing:  This testing is done to measure the thickness of all work piece and products.  This is to make sure we provide our clients with products that meet their specifications.  The thickness tester is used for this purpose.

Color testing:  This is using the colorimeter to measure the color of manufactured parts.

Why Is Aluminum Most Widely Used By Pressure Die Cast Manufacturers?

Aluminum is the most preferred material for die casting by most pressure die casting manufacturers in the world.

This is because aluminum has some unique properties which help to achieve most manufacturing goals.

Sunrise Metals is the No.1 aluminum die cast manufacturer in China. We have capitalized on the unique properties of aluminum to create excellent products that bring great value to all industries.

The following are some of the unique properties of aluminum that makes it preferred over other metals:

• Aluminum is light in weight but strong and hard. This makes it suitable for manufacturing lighter parts.
• Aluminum is a good conductor of heat and electricity. This makes it suitable for manufacturing networking and computing equipment in the electrical and telecom industries.
• Aluminum is highly resistant to corrosion.
• Aluminum has good aesthetic properties. This makes aluminum products attractive and provides a good finish.

What Do You Need To Do First Before Contacting a Pressure Die Casting Manufacturer?

You need to set clear objectives before contacting a die casting manufacturer or supplier. You need to know what you want to do or achieve in your company.

When you have clarity about your objectives or goals, it will guide you to determine the type of die-cast product to purchase from the supplier. You need to know exactly what you need from the die cast manufacturer. Ask yourself this question. “What type of pressure die cast product do I need in order to achieve my objective?”

After this, you need to understand the specifications of the pressure die cast product you need. What is the size, thickness, weight, etc. of the pressure die cast you want.

If possible, draw and indicate all the dimensions of the aluminum die cast you want.

You can contact Sunrise metals to help you with the drawings and prototype design of your desired product.

You need to also plan on your budget. How much do you expect to spend? Before you can do this, you need to determine the quantity of aluminum die cast you need.

What Are The Various Types Of Finishing Work Done By Pressure Die Casting Manufacturers?

There are numerous surface finishing processes that are used by pressure die casting manufacturers. For the purpose of this guide, we will limit ourselves to a few of them.

Plating: This is a surface finishing process whereby a metal is poured onto a conductive surface.

Sanding: This is a surface finishing process whereby a die cast product is made smooth by applying sandpaper on it.

Passivation: This is a die casting finishing process whereby free irons on cast metal are removed. The free irons are removed using nitric acid or citric acid. This process helps to make the die cast product corrosion resistant.

Polishing: This is a popular polishing technique that smoothens a pressure die cast product by applying an abrasive on it. The abrasive is glued to the work wheel.

Buffing: This die cast surface finishing process uses a finer abrasive to improve the smoothness of a surface.

Sandblasting: This is a surface finishing process whereby abrasive beads are applied onto a surface to make away unwanted materials.

Electro-polishing: This involves applying a chemical on a stainless steel surface to improve the smoothness of the surface.

Electroplating: This is coating a metal surface with another metal layer using electricity.

Painting: This is the process of applying paint onto a die cast surface to improve its look using a brush. Like many other finishing processes, painting protects a die cast surface from rusting.

Anodizing: This surface finishing method is aimed at improving the mechanical properties of the material by adding an iron oxide layer to it.

Dip coating: It involves dipping a product into a material coat.

As the leading pressure die casting manufacturer in china, we use the best surface finishing methods that make our products last long.  Using the best surface finishing processes also makes our products highly attractive.

All our surface treatments are ROHS and REACH compliant. Some of the surface finishing treatments we give to our products include:

• Shot Blasting
• Powder Coating
• Liquid Painting
• Electroless Nickel
• Anodization
• Silk Screening
• Pad Screening
• Chromate-Surtec 650

How Does Pressure Die Casting Manufacturers Choose Materials For Their Production?

The first thing manufacturers consider before choosing a material for any project is to clearly define what they want to do or achieve.

Manufacturers need to determine the requirements of their die casting project.

This knowledge guides them to choose a suitable material for their project.

This is because different materials serve different purposes. For example, manufacturing an automobile part will require different materials from making an electrical field.

After deciding on what they want to produce in order to achieve their objectives, manufacturers consider the factors below:

• The composition of the metal alloy
• The mechanical and physical properties
• The chemical composition
• Costs of alloy

For example, aluminum is a preferred option when manufacturing equipment for the automobile, lighting, and computing fields.

What Are Some Of The Medical Equipment Produced By Pressure Die Casting Manufacturers?

Pressure die casting manufacturers use die casting to create different products for different market needs and purposes.

Sunrise metals is China’s leading pressure die casting manufacturer and we create many value-added products that serve a broad market. We can supply your business or company with highly valuable products that would meet all your needs and put you on the path of unending success.

In the medical industry, these are some of the products sunrise metals have created:

What Are Some Of The Automotive Parts Produced By Pressure Die Casting Manufacturers?

The automotive industry is one of the biggest markets in the die casting industry.  The automotive industry’s market share is expected to increase in the coming years.

In order to meet the market demands of the automotive industry, Sunrise Metals has developed a lot of expertise in producing quality automotive parts in higher volumes.

Under the automotive market segment of pressure die casting, Sunrise produces the following products:

• Engine
• Body and chassis component
• Safety parts.

These are some of the high-value products Sunrise metals have for the automotive markets.

What Is The Minimum Quantity Of Products That Can Be Ordered From A Pressure Die Casting Manufacturer?

High pressure die casting manufacturers have different policies when it comes to the quantity of product or manufacturing parts that can be supplied to companies at a time.

Sunrise metals, China’s top pressure die cast manufacturer has a very flexible policy about the number of products that can be supplied to companies.

Sunrise metal’s mission is to create and deliver high mix, low volume projects at the very time you need it.

The minimum quantity of prototyping parts that can be delivered to your company is 1.

When it comes to mass production, we supply our clients with quantities ranging from 100-5000 pieces for all our products.

Prototyping parts quantity: ≥1

Mass production quantity: 100-5000