Die Casting Services
CFS Foundry can produce custom non-ferrous metal parts with die casting services. Our die casting process involves forcing molten metal into a mold under high pressure to form the desired shape rapidly.
- High Production Efficiency
- Great Dimensional Accuracy And Surface Finish
- Suitable for Nonferrous Metals (Aluminum, Magnesium, Zinc, etc)
ISO
9001:2015 CERTIFICATED.
10K+
DIE CASTINGS MADE MONTHLY
20+
DIFFERENT TYPES OF CASTING MATERIALS
20+
COUNTRIES SHIPPED
CFS Foundry is a professional die casting company in China. We have both hot chamber die casting and cold chamber die casting capabilities. The die cast metal materials in our foundry are aluminum, zinc, and magnesium. In addition to die casting, we can also provide value added services including heat treatment, machining, surface finishing, etc.
What is Die Casting?
Die casting is one of the main metalworking processes for metal castings. It is operated by forcing molten metal under high pressure into a die cavity. Generally speaking, die-casting molds are firstly precision machined to net shape or near net shape of finished die-cast parts. The material of such molds for die casting is hardened tool steel. Manufacturing of die-casting molds will allow products to be made with perfect accuracy and repeatability. The die-casting process will also produce fine details, such as textured surfaces or names, without requiring further processing.
Die casting is a wise selection for mass-production products for its ability to produce high detailed and high accuracy parts. In our daily lives, we can see lots of products made in die casting process. When you turn the faucet, you open the door knob, and when you drive your car, almost every product or part of the product you use in your daily life is produced using this process.
The die-casting process usually produces parts using primarily non-ferrous metals, such as zinc, copper, aluminum, and magnesium. For steel and iron castings, investment casting and sand casting are the right manufacturing methods.
5 Steps of Die Casting Process
At CFS Foundry, we are equipped with die casting machines ranging from 280T to 1,600T. The die casting process mainly includes 5 steps in below.
Tool and die is the first step for starting the die casting process, which is made up of two halves. Before the die is ready for the next part injection, each die half needs to be first cleaned from the previous injection and then lubricated. The lubrication will help to increase the size accuracy, as well as the number of cavities and side-cores. Also, depending on the material, lubrication may be required after 2 or 3 cycles, not each cycle. After lubrication, the two die halves, which are attached inside the die casting machine, are closed and securely clamped together. Sufficient force must be applied to the die to keep it securely closed while the metal is injected. The time required to close and clamp the die is dependent upon the machine – larger machines (those with greater clamping forces) will require more time. This time can be estimated from the dry cycle time of the machine.
Metal will be first molten and maintained at a set temperature in the furnace. Then transferred into a chamber where it can be injected into the die. Due to different kinds of die casting machines, whether hot chamber or cold chamber machines, we can decide the method of transferring the molten metal. Once molten metal is transferred, it will be injected at high pressures into the die, normally from 1,000 to 20,000 psi. Under the workforce of high pressure, the molten metal will get solidification. The amount of metal that is injected into the die is referred to as the shot. The injection time is decided when the molten metal fills all of the channels and cavities in the die. Typical injection time is very short, just less than 0.1 seconds, in order to prevent early solidification of any one part of the metal. Besides, The injection time can be affected by the thermodynamic properties of the material and the wall thickness of the part. Of course, larger wall thickness will cost longer injection time. For the cold chamber die-casting process, we still need to count into the time to scoop the molten metal into the shot chamber manually.
After molten metal is injected into the die cavity, it will begin to cool and solidify. Finally, the shape of the casting is formed when the entire cavity is filled and the molten metal solidifies. Only after the casting is solidified can the die be opened. The cooling time can be estimated from several thermodynamic properties of the metal, the maximum wall thickness of the casting, and the complexity of the die. Longer cooling time will be required for greater thickness. Besides, the complex shape of the die cavity may also require a longer cooling time due to the additional resistance to the flow of heat.
When cooling time is enough, the die halves can be opened, and the casting will be pushed out of the die cavity by an ejection mechanism. The time to open the die can be estimated from the dry cycle time of the machine and the ejection time is determined by the size of the casting’s envelope and should include time for the casting to fall free of the die. As the part shrinks and adheres to the die during the cooling process, the ejection mechanism must apply some force. The die will be clamped shut for the next injection after the previous casting is ejected.
During cooling, the material in the channels of the die will solidify and be attached to the casting. This excess material must be removed. The trimming way from the casting could be either manually cutting or sawing or using a trimming press. The time required to trim the excess material is mainly determined by the size of the casting’s outline. After trimming, the scrap material can be recycled for other die-casting production or discarded. Recycled material may need to be reconditioned to the proper chemical composition before it can be combined with new metal for die casting process.
Why CFS Foundry for Die Casting Services?
CFS Foundry is a die casting company providing one stop solution, which includes mold design and development, die casting, machining and surface treatment. Our company is equipped with advanced production equipments, including 200T, 280T, 500T, 800T, 1,200T, and 1,600T die casting machines, and has vacuum die casting technology.To guarantee the quality, we are also equipped with CMM, spectral material analyzer, tensile tester and other testing instruments.
Our company mainly produces automobile and motorcycle die casting parts, monitoring equipment die casting parts, lamps die casting parts and all kinds of customized die casting parts. Currently, we have passed the IATF 16949:2016 quality system certification. In the future, we will still strive for providing high quality products with fast delivery. If you are looking for a reliable die casting company in China, CFS Foundry is your right partner to work with!
Die Casting Types At CFS Foundry
Hot Chamber Die Casting
Hot Chamber Die Casting is the process mainly for metals like zinc, tin, lead and magnesium alloys. In hot chamber die casting, the injection system is immersed in pool of molten metal hence the name. The furnace is attached to the machine via a feeding system called a gooseneck. As the cycle begins the piston will retracts, which allows the molten metal to fill the “gooseneck” from a port in the injection cylinder. As the plunger move downwards, it seals the port and forces the molten metal through the gooseneck and nozzle into the die. Once the metal solidifies, the plunger will pull upwards. Afterwards, the die will open and the part is ejected.
Cold Chamber Die Casting
Cold Chamber Die Casting is the process primarily for aluminum, magnesium, and copper. In cold chamber die casting, it uses a spoon to transport the molten metal from the holding furnace into the unheated shot chamber or injection cylinder. This metal is then shot into the die by using a hydraulic piston. Compared to hot chamber die casting, cold chamber die casting requires transferring molten metal into the cold chamber machine, so the production process is relatively slower. At CFS Foundry, we mainly produce aluminum die castings with our cold chamber die casting machines.
Die Casting Metal Materials
Aluminum Die Casting
Aluminum is lightweight, stable, and it has good mechanical properties, making it an excellent alloy for the die casting process. Common aluminum alloys for die casting include: Aluminum ADC12、A360、A380, and so on.
Magnesium Die Casting
Magnesium is the right material if your die cast part requires lightweight with an excellent strength-to-weight ratio. We can use magnesium AZ91D or AM60B for die casting.
Zinc Die Casting
Zinc is an ideal metal for die casting because of its strength and resistance to corrosion and low melting point and fluidity. Examples of zinc alloys for die casting are: Zamak 3, Zamak 5, Zamak 2, ZA8, and more.
Copper Die Casting
Copper alloy die casting has the highest mechanical properties and corrosion resistance of all die casting parts. Lots of copper alloys can be used for die casting, such as ZQA19-2, ZQA19-4, ZQA19-7, ZQA19-10, etc.
Die Casting Surface Finishing Options
| Surface Finish Type | Image | Description |
| As Cast Finish |  | It is the simplest finish of die cast parts without additonal operations. The surface may still exsit ejector pin marks or parting lines. The mold quality and casting production process will directly affect the as-cast finish appearance. |
| Bead Blasting |  | This process involves propelling a stream of abrasive material against the surface under high pressure. It’s used to create a uniform matte or satin surface finish on die-cast parts, removing surface defects and providing a smooth surface effect. |
| Powder Coating |  | A dry finishing process where a powder material is sprayed onto the surface of die cast parts. It can form a thick and uniform protective layer, which is more durable and resistant to chipping, scratching, and fading compared to liquid painted finish. |
| Anodizing |  | This electrochemical finishing process can form protective oxide on the surface of die cast parts. It can not only achieve decorative colors, but also enchances corrosion resistance, surface hardness, and wear resistance. |
| Electroplating |  | Involves the coating of the die-cast parts with another metal (such as chrome, zinc, or nickel) through an electrochemical process. Electroplating can enhance appearance, corrosion resistance, and surface hardness. |
| Painting |  | Coating die cast parts with liquid painting can not only improve appearance, but also provide additional protection against corrosion and wear. There are several color options and the cost is also lower than powder coated finish. |
| E-Coating |  | A surface finishing technique that uses charged paint particles to coat die cast parts. It’s widely used for its ability to coat complex shapes uniformly and protects die cast parts from adhesion and corrosion. |
Gallery of Die Cast Parts
Die Casting Industries Served
Automotive Industry
In the field of modern automotive manufacturing, die casting is playing an increasingly important role for producing automotive parts. This efficient manufacturing technology brings many advantages for vehicle performance, safety and reliability.
Lighting Industry
Die casting process can produce complex shape parts with high precision, high durability and high consistency, so it has a wide range of applications in the lighting industry. Typical die cast lighting parts including light housings, heat sinks, and more.
Aerospace Industry
Die casting is ideal for aerospare application because of its ability to create intricate aerospace components. CFS Foundry specializes in producing components for the aerospace industry with our die-casting process, such as gears, pistons, and housings.
Electrical industry
The electrical industry also relies on die casting for producing precise components. Typical electrical components made from Die casting include: switchgear, panel boards, and circuit breakers, and so on.
Furniture Industry
Die casting is an excellent manufacturing method for producing intricate metal components for the furniture industry. Typical die cast furniture parts are: office chair base, door handle, arm rest, hingers and brackets.
Construction Industry
In the agriculture industry, die casting is vital in enhancing productivity, improving quality, and reducing costs.CFS Foundry has rich experience in making window frames, cladding, and other structural components from die cast metal.
Die Casting FAQs
Die casting is a good choice when your designed part requires light weight while maintaing high strength, high dimensional accuracy and good surface finish. CFS Foundry can also provide redesign service when your design is not suitable for die casting production.
As the most efficient metal casting process, die casting offers several advantages. First of all, it can produce parts with thin wall thickness, which is not available by sand casting or gravity die casting process. Secondly, it has the ability to make complex parts with close tolerances and smooth surface finish, which will greatly eliminate or reduce post machining operation. Lastly, it can support production in large volume with fast speed.
The main disadvantage of die casting is that, it is only limited to non-ferrous metals, such as zinc, aluminum, magnesium, etc.
By working with CFS Foundry, you can enjoy competitive prices while same good quality when comparing with the US die casting companies. Also, we can provide one stop solution to deliver finished parts, including cnc machining and surface finishing.
Usually, it will take us around 30 working days to finish the mold and samples, and another 40-50 working days for die casting mass production.
More Die Casting Resources
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Die Casting vs. CNC Machining
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