Cold Chamber Die Casting

Inox Cast Cold Chamber Die Casting

Inox Cast is one of the leading cold chamber die casting experts. We have gained more than 20 years of development and history in R&D plastic moulding, prototype designing, two shots moulding, polishing, machining, and surface coating of final products.

Since founded in the business, Inox completely dedicated to supply the latest conditioned products from the cold chamber die casting process.

This process, which called the cold chamber die casting process is the most favored production method for metals which having high dissolving points and corrosive characteristics. Commonly, this will cover metal alloys of zinc alloys, aluminum alloys, copper, and brass. The main essential for cold chamber die casting includes ladle and furnace.

Inox cold chamber die casting process is familiar for its capacity to create thicker metal castings. Unlike hot chamber die casting, Inox cold chamber die casting resolves corrosion issues by doing separating of melt pot from the injector element.

There are several advantages Inox cold chamber die casting offers that include being cost-efficient and effective. It creates a diverse range of elements and shapes.  This process also creates parts that have a long durability. Other advantages involve increasing weight and strength, offers dimensional stability, quick production, and simplified fabrication.

Inox supplies cold chamber die casting solutions to a broad range of industries with different applications. Most of our customers commonly require superior quality products and we export finished products at competitive costs. You can assure all our products have higher strength capacity and evaluative tolerances.

Inox is consists of more than 1000 skillful employees and has started in business in 1997. For many years in the service industry, we can guarantee a satisfying products and services.

Enquire now for further information regarding our cold chamber die casting. And if you like to discuss your concerns, give us a message. You will definitely find out the best way we can help you!

Cold Chamber Die Casting: The Ultimate FAQ Guide

This is a complete guide to cols chamber dies casting.

It covers everything you need to know about cold chamber die casting in detail.

So, keep reading to learn more.

What Is Cold Chamber Die Casting Process?

This is a branch of the die casting manufacturing process ideal for metals that have high melting points and corrosive properties such as aluminum.

This method helps in solving the corrosion problems by separating the melting pot from the injector component, unlike the hot chamber die casting method.

In this method, the metal is liquefied in a furnace at a high temperature and then the metal is transferred into a cold chamber by ladle to be injected into dying.

The cold chamber is also capable of die casting metals with low melting points but in rare circumstances.

However, considering the advantages, the hot chamber dies casting method makes more economical sense to use for low melting point metals such as magnesium, zinc, etc. hence it is recommended for such tasks.

A Cold Chamber Die Casting Machine

What Are The Benefits Of Cold Chamber Die Casting?

Cold chamber dies casting is one of the excellent methods in the production of metal parts.

Some of the benefits that accrue from this method include;

• Excellent dimensional stability during the die casting process- this ensures that the metal parts maintain close tolerance throughout the process of casting.

Additionally, the die casting method also provides excellent dimensional accuracy.

• Improve surface finish- this method results in perfect surfaces with good appearances and an even distribution of porosity unlike other methods like a sand process that involve the use of sand.
• Ideal for mass manufacturing/higher production rates- the machines used in cold chamber die casting can be designed to have high production capability hence ideal for mass production.
• Cast metals directly- this method is usually referred to as the directly cast technology since there is no expendable production steps involved.
• Highly versatile range of alloy options- different alloys can be used for cold chamber die casting especially those with a high melting points while still offering excellent mechanical properties to the alloy such as corrosion resistance, tensile strength.
• Has shorter cycle time- this casting process takes the shortest time possible due to the fluidity of the metal alloy as compared to other processes i.e. permanent mold process.

Therefore, the shorter the time means the shorter the cycle leading to a significant increase in the production rate.

• Low machining requirements- compared to other methods such as sand or permanent mold processes, this method does not require machining after the casting process of milling, turning, etc.

Parts produced by this casting process only require a little amount of post finishing before being put to use.

Therefore, it means that there is a significant increase in the productivity rates since there will be less time dedicated for additional steps like drilling holes, grinding, polishing among others.

• Long-lasting and robust components- this type of die casting method helps in creating metal parts that are stronger, long-lasting and the components robust.
• Cost-effective- the method is effective and saves more on the cost since it does not require a lot of machining such as milling, turning

You Get Long Lasting Components From This Process

What Are The Application Areas Of the Cold Chamber Die Casting Process?

The cold chamber dies casting method has a wide variety of applications and this is as a result of the benefits that accrue from using this type of die casting process.

This die casting process is ideal for metals with high melting points therefore, the application areas can be based on the metal alloy used or can generally be based on the process.

So, some of the applications of this process based on the metal alloy used include;

• Aluminum dies casting applications- used in a vast number of industries like the automotive industry where the die-cast aluminum parts have been used as a replacement for iron and steel parts.

Used in the aerospace industry due to its lighter weight which helps in reducing fuel consumption as well as facilitating the movement of airplanes.

The product of die-cast aluminum alloy can also be found in housing and electronic connectors and this is as a result of its excellent electrical performance and its shielding properties.

Additionally, aluminum die-cast products can also be used in the building and construction industry for example in curtain railings, window frames, fitting, cladding, partitions among others.

Die Casting Of Aluminum

• Magnesium dies casting application- mostly used in electronic casing and housings in making of protective housings/casings for smartphones, laptops, tablets, etc.

This is due to their good conductive ability hence are capable to shield against electromagnetic and radio interference.

The product is also used in the automotive industry especially in high-performance vehicles like sports cars since they are lightweight thus reducing the vehicle’s weight, increasing its speed and fuel efficiency.

Magnesium dies casting products can as well be used in the aerospace industry.

They are also the choice option for aircraft and spacecraft due to their high insulation properties, durability, and lightweight.

Magnesium Is Lightweight Thus Commonly Used In Aircraft And Speed Cars

• Zinc die casting applications- die-cast zinc alloy has excellent shielding properties as well as electrical performance thus used in the electrical and electronic sector.

Die-cast zinc product is also important in the automotive industry due to its strength and hardness hence can be used in the air conditioning system of the vehicle, brake system, and fuel system.

Besides that, this alloy is also ideal for multifaceted, complexed shaped products due to its easy castability.

Apart from cold chamber die casting is ideal for metals with high melting points, the process can as well be used in metal alloys having low melting but on rare occasions and an example is tin alloy.

Therefore the application of tin die-cast through cold chamber include;

-used in decorative items and costume jewelry.

-used for precision parts and bearing of household appliances, engines, gas turbines, motors, and generators.

Most of the food handling equipment is manufactured from tin castings since the metal alloy is non-toxic.

Can Cold Chamber Be Used To Cast Low Melting Point Alloys?

Yes of course, it is possible to use this type of die casting to cast low melting point alloys like tin, magnesium, zinc only if there is no other alternative available.

But generally, cold chamber dies casting should be used for high melting point alloys considering its advantages.

Normally, metal alloys with low melting points are preferred to be used in a hot chamber using the hot chamber die casting process since it is more advantageous as compared to the cold chamber method.

What Are Some Of The Metal Alloys Used In Cold Chamber Die Casting?

The cold chamber dies casting method is usually ideal for metals alloys having high melting points.

However, it is also possible to cast metal alloys having low melting points using this method but considering the advantages, the cold chamber method might not be the best.

The following are some of the metal alloys used in cold chamber die casting and their advantages;

Aluminum- This metal alloy has a high melting point and excellent corrosive properties making it suitable for the cold chamber die casting process.

 Aluminum Can Be Used In Cold Chamber Die Casting

Besides that, it has the ability to withstand high temperatures, strong dimensional stability, lightweight among other properties.

Copper- this is also another metal alloy used in the cold chamber method.

This metal alloy has a high ability to resist corrosion, excellent strength and hardness, good dimensional stability, high wear resistance, high mechanical properties among others.

Silicon tombac- simply a combination of zinc, copper, silicon and it is high in strength.

Zinc alloy with aluminum content- has a high strength to impacts, easy to cast, high ductility, easy to plate, promotes long life for the dies that are being used, and is also cost-effective.

Zinc alloy can utilize both cold chamber and hot chamber die casting processes.

Magnesium alloy- it is stronger and stiffer, provides resistance to corrosion, and is better suited to large, thin-wall net-shape complex parts.

But most importantly, it has a high melting point making it ideal for this process.

Apart from these, there are also other materials such as lead, brass, tin that can be cast using the cold chamber die casting despite some like tin having a low melting point.

How Do You Compare Cold Chamber Die Casting And Hot Chamber Die Casting?

Both of these two casting processes are the branches of die casting most commonly used in the manufacturing industry.

However, there are some features and properties that separate the two and they include;

In cold chamber die casting, metal is heated in a separate furnace and then newly molten metal is transferred to the casting machine using a ladle.

Hot chamber on the other hand involves heating the metal alloy in a casting machine rather than in a separate furnace or machine.

Cold chamber dies casting is suitable for metal alloys with high melting points such as aluminum alloy, copper, magnesium, and even zinc since it can be utilized by both the two die casting processes.

Hot chamber dies casting on the other side, is suitable for metal alloys having low melting points i.e. tin, lead, zinc, and the alloys are only limited to metals that won’t erode or dissolve the machine under heat.

Cold chamber dies casting requires a lot of pressure as compared to hot chamber die casting to inject the molten metal into the die.

Cold chamber dies casting machinery requires a high-pressure hydraulic plunger to inject the molten metal into the die whereas hot chamber machinery uses gooseneck to inject material from pot to die.

In terms of the cycle time, the hot chamber dies casting method is much faster and has a short cycle time i.e 15 cycles per minute as compared to the cold chamber.

The short cycle time is a result of the hot chamber machine having a melting pot inside it.

How A Hot And Cold Chamber Compares

How Does Cold Chamber Die Casting Machine Work?

In order to understand how the cold chamber machine operates, first you need to be well conversant with the components and parts of the machine i.e the pressure chamber, upper punch, mold, nozzle, etc.

Therefore, during the die casting process, the pressure chamber is normally placed vertically and the upper punch above it.

Then the lower punch is located where the nozzle orifice is blocked and this helps in preventing molten metal from pouring into the pressure chamber and moving into the nozzle hole by itself.

The opening and the closing movement of mold move horizontally and if the mold is opened, the die casting remains in the movable mold.

Therefore to start operating the cold chamber die casting machine, you first need to close the mold, then pour molten metal into the pressure chamber either manually or using other means such as a ladle.

The upper punch will then move down slowly and enter the pressure chamber at a lower injection speed until it touches the molten metal surface.

After that, the upper punch is turned to a higher injection speed and pressed down.

This will cause both the upper and the lower punch to move down synchronously while still maintaining the distance between the molten metal and the upper punch.

Lower punch is normally located at the nozzle orifice, so when the punch is moved down, it let out the nozzle orifice descends and gets supported at the nozzle part.

Both the lower punch and upper punch will then squeeze the molten metal to the nozzle hole injection at a high speed.

The molten metal is filled into the mold cavity through the sprue composed of the nozzle.

Once the filling is done, the upper punch will maintain a particular pressure until all the molten metal in the cavity is solidified completely into die casting.

There are those molten metals in the pressure chamber and in the runner, they will also solidify into the direct gate and the remaining to cake.

After that, the lower punch is moved down and reset to block the nozzle orifice.

The mold is then opened, the die casting part and the straight gate remains on the movable mold together.

Eject and take out the die casting part.

How A Cold Chamber Die Casting Machine Works

Does Cold Chamber Die Casting Process Have Limitations?

Of course yes but the benefits or the advantages of this cold chamber method outweighs the disadvantages.

First, the cold chamber die casting method has a slower production cycle and longer when compared to the hot chamber die casting method.

This is because the molten metals in separate cold chambers can cool down before the injection is done.

There is also one more step required in the cold chamber method than in the hot chamber method that makes the cycle slower.

In this process, the molten metal can easily get contaminated, oxidized, or have quality problems if the production floor does not have strict quality control measures.

Is Cold Chamber Die Casting Process Suitable For Producing Thin Parts?

Yes, it is possible to produce thin parts using the cold chamber die casting process.

Despite the cold chamber die casting method using high pressure during the manufacturing process, it is still suitable for the production of thinner parts of up to 1mm and lightweight components.

The thinner parts and the components produced through the process are used in various areas such as the aerospace industry and even in the automotive industry.

What Is The Best Temperature For Die Casting Process Using Cold Chamber?

Temperature change has diverse effects on the cold chamber die casting process.

The temperature range may differ depending on the kind of metal alloy being used but generally, an increase in temperature will decrease the tensile and strength yield in the die-casted alloy.

On the other hand, the ductility of the metal alloy increases with an increase in temperature, but changes depending on the metal alloy being die-cast.

When using this die casting process, the temperatures that should be closely monitored for the success of the manufacturing process include;

• The temperature of the metal alloy used.
• The temperature of the die.
• The temperature of the cold chamber or die casting chamber.

Therefore, in order to produce high-quality die-cast parts, you need to ensure that the above temperatures are at their optimum range.

The temperature of the die should be approximately one-third that of the metal alloy.

Generally, the optimum temperature range of die is around 50-to-70-degree Celsius and this is always the best temperature range to pour your metal alloy into your die.

On the other hand, the temperature of the cold chamber/casting chamber does vary depending on the size of the part to cast, type of alloy, type of die, and other factors.

Therefore the optimum temperature range of the casting chamber can only be determined by an experienced die caster when the above factors are put into consideration.

But if the temperature of the cold chamber is too cold, this may cause the molten metal to cool much faster as it flows into the mold hence causing some defects.

The temperature of alloy will also depend on the type of metal alloy being used, for example, aluminum has a temperature range of 190-315 degrees and zinc 190-290 degrees on the average finish.

How Much Does Cold Chamber Die Casting Processes Cost?

The cost of this type of die casting process is categorized into three i.e. the casting production cost, mold cost, and the cost of the material.

The casting production cost depends dearly on the cycle time and the hourly rate [the hourly rate is proportional to die casting machine size].

The cycle time of the casting process includes the resetting time, cooling time, and injection time.

A decrease in the cycle time will result in a decrease in production which is a little bit cheaper as compared to having a longer cycle time.

Furthermore, the production of large die casting parts is more expensive than producing smaller die casting parts.

Under mold cost, you can use core to lower its cost especially for those parts with similar designs but used on other models with partial modifications.

In situations like this, we can consider making different parts into a core and a pair of molds to make a variety of products which is cheaper.

Typically, the cost of the cold chamber die casting process ranges between 750 and 1500 euros but the exact cost will depend on a number of factors i.e. complexity of the cross-section, size of the die, etc.

How Much Of Injection Pressure Can Be Used On The Cold Chamber Die Casting Process?

Cold chamber dies casting utilizes a lot of injection pressure [over 10,000psi or 70,000 KPa].

Normally after the molten metal alloy is injected into the die cavity, the plunger remains forward to hold the pressure as the casting solidifies.

Does Cold Chamber Die Casting Process Have Effects On The Material Properties?

To some extent, changes in temperature can have some impacts on the mechanical properties of the material during the die casting process and this can affect both metal flow and casting quality.

For example, an increase in temperature can result in a decrease in the tensile and strength yield of the die casting metal alloy.

Ductility on the other hand will increase with an increase in temperature but this is more influenced by the type of material used.

To avoid some of these effects from occurring, you need to ensure that the cold chamber die casting machine is at its optimal temperature range before the die casting process begins.

Why Are Aluminum Alloys Cast In Cold Chamber Die Casting Machines Rather Than Hot Casting Machine?

Generally, most materials used in cold chamber die casting machines, are those metals with high melting points and also resistance to corrosion.

Aluminum is a metal alloy having a high melting point, excellent corrosion properties, strong dimensional stability, and also has the ability to withstand extreme temperatures.

These properties make most of the aluminum castings be produced only in cold chamber die casting machines.

Another advantage of cold chamber die casting machines is that it is suitable for die casting non-ferrous and ferrous metals, and aluminum being non-ferrous makes it suitable to be cast using this machine.

Hot chamber die casting, on the other hand, is only suitable for metals with low melting point and therefore aluminum cannot be used since it may pick some of the irons while in the molten pool.

What Are The Parts Or Components Of Cold Chamber Die Casting Machine?

This is a machine used for casting metals with higher melting points such as copper, aluminum, magnesium, zinc alloy with high aluminum content.

Some of the basic components or parts of the cold chamber die casting machine include; ejector pin which pushes out the casting out of the ejector, plunger which pushes molten metal to the die cavity.

Others include; the ladle, ejector die, cover die, core, hydraulic cylinder, movable platen, short chamber, rear platen, clamping bar, sprue, clamping unit, tie bar, casting among others.

Is It Possible To Produce Complex Shapes And Sizes Of Metal Alloys Using Cold Chamber Die Casting Method?

It is possible to produce metal alloys with different shapes and sizes using the cold chamber die casting method.

The cold chamber machine is designed in such a way that enables it to produce parts with complex shapes and it does so with closer tolerances than any other production process.

The castings can be produced in a range of sizes from 0.75 by 0.75 to 18 by 18.

Therefore, the size and shape of die-cast metal alloy will depend on the application requirements.

What Are Differences Between The Centrifugal Casting And Die Casting?

Centrifugal casting

Centrifugal casting is a molding casting method whereby the molten metal is taken into a high-speed rotating metal mold by the use of a centrifugal casting machine.

The mold is rotated at a high speed and driven by centrifugal force to cool the crystal.

Die casting, on the other hand, is a manufacturing process whereby the molten metal is injected or forced into a mold cavity or dies.

In centrifugal casting, the utilization rate of metals can be up to 80-90% while die casting is not efficient due to the presence of gates, runners, and slag packs.

For all your cold chamber die casting needs, contact us now.