Copper Die Casting

Excellent Copper Die Casting Provider – Inox Casting

If you`re in need of a copper die casting process or products, Inox Casting got you covered. Inox Casting specializes in providing high-quality castings that suit every customers’ right specifications. Using the finest quality materials such as copper, Inox produced a wide range of parts and components for your particular requirements. As a professional copper die casting expert, you can avail of it at a very cost-effective rate.

Inox Casting’s experience is unparalleled in the design, development, and manufacturing of precision copper die-cast solutions suitable for a broad range of automotive applications, construction machines, connectors parts, telecommunications parts consumer electronics parts, the electric utility industry, and so on.

Our Inox Copper die casting offers high durability and hardness, good wear resistance, good dimensional stability, high corrosion resistance, and the highest mechanical properties of alloy die casts. Inox copper die casting is often an outstanding method for efficient fabricating of copper parts and components and has a high level of engineering skills and high-volume production.

Inox Casting also works closely with clients through every step of the process, from unique R&D, design, manufacturing to completion, you can trust our management system. Our copper die casting factory possesses advanced and innovative copper die casting production line. We are also supported by much professional staff, designers, and technicians willing to help you to the success of your project.

High-quality production is always the main priority at Inox Casting. We strive to exceed all customer requirements and expectations and offer comprehensive engineering services and on-time delivery of high precision machined parts, copper die casting best surface treatment, castings, forgings, fabrications, etc.

For the Inox copper die casting surface treatment, we provide powder coating, painting, chrome plating, e-coating, anodizing, and impregnating. Whether you require a smooth or textured surface finish for your copper requirements, Inox copper die casting can produce components that match your demands and applications.

We are your expert copper die casting service provider. Aside from copper die casting, we also offer titanium die casting, magnesium die casting, zinc die casting, aluminum die casting, and many more. In short, Inox Casting is your one-stop provider with rich experience and history in this field.

For more information about Inox copper die casting, don’t hesitate to message us. We have 24/7 online support to help your business grow.

Copper Die Casting: The Ultimate FAQ Guide

In this guide, you will find all information you are looking for about copper die casting.

So, before starting your next copper die casting project, read this guide.

Why Die Cast Copper?

The die cast copper ought to be used due to the following reasons;

Materials die casted using copper offer an exemplary higher resistance to any corrosion that ranges from physical and environmental corrosion.

Also, die casting materials or other components using copper, offers higher hardness levels to the materials, parts and components.

In addition, due to the properties of copper, it offers wear resistance.

The wear resistance is excellent to the materials and components which have been die casted by it.

die cast copper

Moreover, amongst all the alloy die casts, copper die cast has the highest mechanical properties as compared to the others.

Furthermore, the die cast copper has a great dimensional capacity as it is rigid and tough and at the same time.

Due to its dimensional capacity, it offers a response that is minimal to wear and tear over long periods of time.

Still, when it comes to strength, the die cast copper is as strong as its strength can match that of steel parts.

Are There Limitations Of Copper Die Casting?

Yes, there are limitations of the copper die casting.

Some of the most critical limitations of the copper die casting include the following;

Porosity Is Common During Copper Die Casting Process

In the melting process, the mold cavity fills at very high speeds.

It should be put under consideration that the mold material is not permeable to gas.

The presence of porosity in the copper die casts may lead to adverse effects like component failure of the die casted parts.

The following are types of porosities that can happen on the copper die casts;

To start with, blind porosity is the one that is responsible for the internal corrosion of the components and parts.

This type of porosity also causes adverse defects on the surface parts in the case where secondary treatments are applied.

The reason behind defects occurring when surface treatments are done is the solutions used initially in the cast cleaning.

The initially used solutions leech out from the voids after the process of surface finishing is done.

Secondly, when the through porosity is on the copper die casts, this will also adversely affect the component or part.

The component or part is affected by creating a failure point since the integrity of the structure would have been compromised.

The casting should always provide the pressure tight property to the components or parts.

Hence, when there is through porosity, the part is not pressure tight.

Therefore, the performance of this parts with through porosity is highly impacted more so if they are to hold fluids or gases.

Additionally, this is a type of porosity that is in the inside of the component and is normally enclosed within the casting.

Since it is enclosed, it does not allow any sort of passage towards the surfaces.

This type of porosity is considered not be a big deal most of the times as machining can be used in the uncovering of the porosity.

The porosity will eventually be turned into a through or a blind type of porosity.

Process Of Copper Die Casting Maybe Costly

This type of process demands a higher cost initial capital to start and run the investment.

It really requires adequate funds as you to acquire everything and set up the process at one time.

The equipment of casting dies and other components that are essential to the process are very much costly.

Because of cost, the process is suitable for the high volumes of production only.

Process Is Only Suitable For Large Volume Production

This process is economical when doing large batches of production since it uses casting molds hence making the entire process being repeated.

Repeating the process very many times, it creates metal casts that are identical all through the way.

Unlike in the small scales of production, the molds demand to get changed to produce specific looks on the parts or the components.

That makes the process to be so much expensive as the components and parts are produced in small quantities.

At the same time, the cast molds need to be changed at the same time thus it becomes costly.

A Lead Time That Is Too Long Is Witnessed

Die-casting of copper takes longer for the process to be fully done and the casted components getting delivered.

The process involves many aspects that must be followed by order for you to have a great final product of your desire.

Some of the key factors that determine the lead time of process include;

When the order is placed and at the same time before order placement is the manufacturer having parallel orders from other clients.

Also, at times the order given might not be having a good visibility thus the manufacturer spending more time while seeking clarifications.

Additionally, the complexity of the part will also be a time factor as more complex parts will take a little longer.

Moreover, the volume being casted will determine the time frame that will make the final products ready.

A higher volume is going to take longer.

Furthermore, the amount of testing required to be performed and the volume of parts to be tested also has an impact on the lead time.

This is because each part has to undergo an individual test.

The tests and parts, the more the time it is going to take to complete each individual test and each part.

Which Temperature Is Suitable For Copper Die Casting?

The suitable temperature in the die casting copper is 550°C.

How Does Copper Die Casting Compare To Aluminum Die Casting?

The following is how a copper die casting compares to the die casting of aluminum;

In terms of cost, the die cast of copper is much more costly than that of aluminum.

copper die casting

The reason behind that is copper goes through a lot of complex processes than that of aluminum.

A core factor that makes the die casts of copper to become more expensive is higher temperatures of processing.

The higher processing temperatures demand in high tonnage equipment which is more complex.

Also, the cost of raw materials is high for copper as compared to that of aluminum die cast.

Besides, copper die cast also require tooling that is more advanced and complex.

Efficiency, when it comes this, copper die casting is more efficient than using the die cast of aluminum as it offers great properties.

aluminum die casting

Despite aluminum die casts offering fair properties, copper outshines them with a very large margin.

For instance, the electrical conductivity of copper is excellent as it is about 160% in relation to that of aluminum.

Moreover, aluminum die casts are fairly light weight compared to the copper die casts which are heavier.

Copper die casts are not appropriate for lightweight applications, same to the aluminum which cannot be used for the heavy applications.

What Are The Features Of Copper Die Cast Components?

The features of copper die cast components include the following;

The copper die cast components are resistant to corrosion that might come from the environment or physical such as pressure.

Since they possess the resistance property it makes it possible for them to be used in wide range of applications.

Copper die components have this distinct property of them offering a higher hardness level thus making them reliable in their applications.

The components die casted of copper offer tear and wear resistance due to their hardness and resistance to corrosion kind of properties.

Furthermore, these components of copper die casts do have mechanical properties that are higher.

Besides, when it comes to strength, components made of the copper die cast are much stronger.

Lastly, these components do offer a great dimensional stability because copper as an element is tough and rigid.

The die cast being tough and rigid makes it to offer a minimal response to tear and wear.

How Does Copper Die Casting Compare To Zinc Die Casting?

The copper die casting compares to zinc die casting in the following ways;

They are both tough die castings since they have an impact strength that is high;

Apparently, it is important to note that the copper die is much stronger than the zinc die cast on terms of impact strength.

copper die casting

Copper die casting and zinc die casting also offer superior performances due to their higher electrical conductivity.

When it comes to rigidity, the copper die casting outshines the zinc die cast since zinc contains the ductility property.

Die casts of copper are more expensive to those of zinc as they require higher temperatures to hit their melting points.

 zinc die casting

How Do You Increase Efficiency Of Copper Die Casting Process?

To increase the efficiency of the process of copper die casting, the following should be done;

A good choice of the raw material to be used should be put under consideration

Good quality raw materials to produce the copper die casting should be chosen appropriately since it directly impacts on the efficiency.

Choice of good material also has an impact on the quality and production of the castings.

A wrong choice of the raw materials is going to lead to poor quality castings thus inefficiency.

Also, when good materials for the process are put in place, there is reduced wear of the mold and its service is extended.

Through that the costs of repair and replacements from time to time are significantly reduced.

Therefore, you need to only cooperate with copper supplier that supplies copper of good quality to increase the efficiency of the casting process.

Having a great mold

You need to have an excellent mold which is modified by timely adding of nitriding thus improving the qualities of hardness.

Improved work belt reduces the rates of repair to be done thus improving the quality of the product.

An improved work belt also reduces the rejection rate.

Through this, maximum yields are produced thus the efficiency is achieved.

Having suitable temperatures

Throughout the copper die casting process, appropriate temperatures should be maintained in order to avoid the unpredictable damages.

The probability of fixing the unpredictable damages is close to impossible meaning that funds and time are going to be lost.

Also, the temperatures need to be stable for you to produce uniform castings on the components for them to look identical

Which Copper Alloys Are Suitable For Die Casting?

The copper alloys suitable for die casting are the ones which do have high compressive and tensile strengths, they are machined easily.

Moreover, they have good conductivity when it comes to thermal and electrical conductivity.

copper alloys

Also, they have great wear qualities and great corrosion resistance properties.

These metals include the following;

Brass, it is an alloy of tin and copper

Bronze, it is an alloy of zinc and copper

Monel or cupronickel which is an alloy of nickel and copper

How Do You Choose High Pressure Die Casting Machine For Copper Die Casting Process?

The following are some of the considerations that should be considered when choosing the high pressure die casting machine;

high pressure die casting machine

The Ton Capacity

The machine being chosen should come with an appropriate ton that is going to serve the intended purpose.

Therefore, the choice of the machine with a certain ton, it depends with the type of task to be performed.

Base Of The Machine

The base of the machine is the designed structure that enables the machine to rest on ground.

Also, the part should be strong enough for it to be able to withstand the weight of the machine and its components.

The base should be able to also support the injection system.

The Exchanger Systems Of Heat

Machine often heat during their functioning and this is due to their running processes.

The processes at times might fail if the heat becomes much and is not controlled in any way whatsoever.

Besides, the heat exchange system of the machine should be keenly inspected and tested during the purchase of the machine.

The reason behind that is to determine its functionality.

Systems Of Die Locking

The high pressure machines use the systems of hydraulic throughout their functioning processes.

Therefore, the mechanism which its value is to support the die locking, it should have the capability to accommodate any type of die.

Systems Of Injection And Ejection

The hydraulic system is essential in the injection mechanism since it is designed to get powered under high pressures.

Also, the ejection system is used to eject a component of the die cast from the die cavity.

The two system s should have a proper inspection to ensure that they function harmoniously before acquiring the machine.

How Does High Pressure Copper Die Casting Work?

This process entails forcing of the molten copper metal under high levels of pressure into a mold cavity that is sealed.

The molten copper is then held by compressive powers that are so much powerful until it attains its solid state.

After the solid state is attained uniformly, the die is supposed to be released, opened thus the metal is the removed.

After the removal, the mold cavity is then sealed again to wait for the next phase.

The entire process repeats itself for the volume of components to be made.

It is important to that; molten copper injection into the cavity occurs so fast due to the higher pressure.

The high pressure is essential because it has to sweep out in gas which had initially been trapped into the cavity.

Also, at the same time feed more metal to compensate metal shrinkage during the solidification process.

What Are The Benefits Of High Pressure Die Casting Of Copper?

The benefits of high pressure die casting of copper include the following;

Higher speeds of production, the process of production is sped up due to the high pressure applied.

Also, the operations of processing are notably reduced due to the capacity to create specific dimension flows.

The process enhances the fusions to have a surface finish that is good; it is normally an essentiality when it comes to plating, also, the plate wall thicknesses are reduced through fusion overall weight reduction.

Durability of the molds, this leads to the reduction of costs of production that can come along as a result in the replacement of the molds.

Complex parts are made easily with this type of manufacturing process.

Why Is Die Casting Pure Copper Difficult?

Die casting pure copper is difficult as it is much prone to defects.

The defects of die casting pure copper include cracking of surfaces, having cavities internally and shrinking of the metal.

Which Defects Are Common In Copper Die Casting?

Some of the common defects in the copper die casting include;

Porosity, this is the situation of bubble formation on the surface of the cast after cooling.

The defect can be done away by having low temperatures maintained during the cooling process.

Also cooling it in a vacuum will also solve the defect.

Shrinking, this is a defect that comes into action as a result of the cast not heated evenly.

The situation can be corrected by ensuring that the metal and mold are having even heat and solidify equally through cooling.

Defects of the mold, they occur often when the metal has not filled the mold in a proper way.

Also, if the mold has cracked, it is also going to cause these defects to occur.

Therefore, it is important to ensure that the mold is I n a proper condition before the metal is poured.

Metallurgical defects, these are types of defects that occur due to lack of even heating of the metal.

At times, the metal can also have some parts hard than the others thus creating the defect.

The process can be undone by having the mold under stable temperatures.

How Can You Increase Efficiency Of Copper Die Casting?

The efficiency of copper die casting can be increased by;

Having appropriate temperatures throughout the process

Good choice of raw materials

Having an excellent mold

What Determines Cost Of Copper Die Casting?

The following determines the cost of copper die casting;

Cost of raw materials

Cost of molds

Cost of production

Does Copper Die Cast Parts Require Heat Treatment?

Yes, they do require heat treatment.

Should You Use Hot Chamber Die Casting Or Cold Chamber Die Casting For Copper Alloys?

For the die casting alloys of copper, you need to use the cold chamber die casting process.

hot chamber die casting

cold chamber die casting

What Are The Advantages Of Copper Rotor Die Casting?

The advantages of copper rotor die casting include;

There is a reduction in the cost of manufacturing

The motor weight is reduced

Efficiency in the motor energy is improved

Which Surface Finish Can You Apply On Copper Die Cast Parts?

The surface finishes that can be applied on the copper die cast parts include;

Plating

Polishing

Anodizing

Chroming

How Do You Test Quality Of Copper Die Cast Parts?

The quality of the die cast can be done through;

The mechanical testing to determine the hardness of the casting

Non-destructive testing where the parts are physically inspected to determine the casting’s integrity.

Dimensional accuracy

Liquid penetrant test

Can Copper Die Casting Produce Thin Parts?

Yes, it can produce thin parts.

Can You Handle Custom Copper Die Casting Process?

Yes, I can.

Which Are Good Design Practices For Copper Die Casting?

Good design practices for the copper die casting include the foll0owing;

Thickness of the walls, the walls of the die cast should uniform when it comes to thickness.

Fillets, the fillets should be positioned on the edges and corners.

Draft, to have the cast extracted from the die, there should be sufficient draft.

What Should You Consider When Designing Die For Copper Die Casting?

When designing the die for copper die casting, you should consider the following;

The metal flow, without trapping any gas, the metal should be able to flow in every area of the die.

Venting, there should be a route of escape of air as the metal is flowing into the die.

Cooling lines, heat from the steel die should be removed by the cooling lines.

Their location matters a lot as they should ensure the die is thermally balanced.

Ejection, the use of ejector pins is utilized in the pushing of the pins out of the die hence they need a good positioning.

Why Are Prototypes Important During Copper Die Casting Process?

Prototypes are important as they as they give a lead in the design you desire during the copper die casting process.

For any questions or inquiry about copper die casting process, contact Inox now.