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Precision Aluminum Die Castings for Motor Parts
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Precision Aluminum Die Castings for Motor Parts

Die casting is a manufacturing process that allows the production of metal parts 
with a high degree of precision. In this casting process, 
molten metal is injected into a mould, 
where it cools and hardens to create the desired shape.

What is die casting?

Die casting is a manufacturing process that allows the production of metal parts with a high degree of precision. In this casting process, molten metal is injected into a mould, where it cools and hardens to create the desired shape.



The method can be used to create various metal parts, from gears and engine blocks to door handles and electrical components.

How Die Cast Metal is Made

Die cast metals are made from a manufacturing process called die casting, in which molten metal is poured or forced into steel molds. These molds, called dies, are made from steel and are specially designed depending on the project. This allows for each component to be created with accuracy and repeatability. Most die casting processes use non-ferrous metals, especially zinc, copper, aluminum, magnesium, lead, and pewter. Depending on the type of metal being cast, a hot or cold die casting chamber may be used.

Smoothing and Polishing Process

After a die cast metal part has cooled off and removed from a mold, it still needs to be polished and smoothed out before it is moved into the next step in production. Excess components called sprues, runners, and flashes are still attached to the model part. These parts are usually removed by hand and returned to the furnace to be melted and recycled. Deformed parts are also returned to be re-used and re-molded. With all the excess components removed, the model part still has rough and sharp edges that need to be smoothed out. Polishing is done through the use of abrasive equipment. Depending on the metal, different equipment like polishing wheels with different grades of abrasiveness are used. For high-volume model polishing, especially those with smaller parts, ball bearing abrasion machines are used to smoothen out edges.

Die Casting Design

Before die casting your part, manufacturers will consider a number of factors, such as: element thicknesses and intricacies (affects the amount of time the metal should spend in mold or molds) and complexity of cast design (affects solidification time). To customize a die casting process for unique requirements, manufacturers can adjust the die design, process heat, the material composition or how long the material spends in a mold.

Machinery Used in Die Casting

Manufacturers can perform die casting using either a hot chamber machine or a cold chamber machine, as well as mold cavities.

Hot Chamber Machine
A hot chamber machine is used for high pressure die casting. Inside the hot chamber machine, molten metal is injected at an extremely high pressure and never separated from the machine.

Cold Chamber Machine
A cold chamber machine uses metal that has been melted in a separate area. The metal is ladled into the die cast machine.

Mold Cavity
The mold cavity is made from two hardened dies. Every die is cut from metal to create a certain shape, and most are made to create closed die castings. The mold cavity works similarly to an injection mold. It does reflect the exact dimensions of the finished part, allowing for occurrences like: machining, distortion draft and shrinkage.

All die casting machinery can be customized per the needs of the application.


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