Die Cast Engine Block

Inox Cast Die Cast Engine Block

Inox Cast is a professional die cast engine block manufacturer for more than 20 years. We focus on manufacturing only the best and highest quality products that will meet your requirements. We are confident about our services top deals for your business.

Inox Cast mainly focuses on OEM die cast engine blocks. We manufacture custom-made die cast engine blocks based on your requirements. Just send us your details and specification. Our engineers will work closely with you to create your ideal die cast engine block.

Our die cast engine blocks are manufactured using high-quality materials to meet its functional requirements. We usually used grey cast irons, aluminum alloys, graphite cast irons, steel, and more. These materials possesses a good mechanical properties, availability, and low cost.

We manufacture die cast engine blocks to give you cost-effective solution. It functions as the main housing of engine and a lot of automotive parts and components. Thus, we created premium quality die cast engine block.

Features of Inox Cast Die Cast Engine Blocks

• Excellent wear resistance
• Long-lasting and easy maintenance
• Withstand high temperature and vibration
• High strength and superior corrosion-resistance
• Modulus of elasticity
• Increased power and durability
• Lightweight and low cost

Inox Cast has been the trusted and world-leading die cast engine block manufacturer for more than 20 years. We are committed to providing customers a cost-effective solution to make your business more successful and skyrocket your projects. We offer cost-effective solution, the best quality products, and excellent customer services globally.

Send inquiries for your next die cast engine block orders!

Die Casting Engine Block: The Ultimate FAQ Guide

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

So, keep reading to learn more.

Which Materials Can You Use For Die Cast Engine Block?

In the past the material that was commonly used in the making of engine blocks was grey cast iron.

Since then the industry has grown and you will find different materials and also the best you can use to build engine blocks.

Some of the materials you can find include aluminum alloys, grey cast iron among many others. Aluminum alloys and grey cast iron are commonly used but there are others and each has its advantages and disadvantages.

die cast engine block

Listed below are the materials used for die cast engine block;

• Aluminum – it reduces weight in engine blocks.
  It is very good in resisting corrosion, its mechanical properties are good, even in temperatures that are high it does retain its strength.
• Grey cast iron – it is very good at resisting wear.
  It is tough and very strong, has a high melting point hence it can handle more heat and it also has good corrosion and lubrication characteristics.
  At the same time it causes poor surface quality and dimensional accuracy due to its high casting and solidification temperatures.
• Zinc – zinc is a very simple to cast metal.
  It has high ductility, it can be plated easily, its impact strength is high and it also ensures long die life.
• Copper – it is very hard, resists corrosion highly, it does not wear easily and it has perfect dimensional stability and strength.
• Magnesium – magnesium has perfect strength, it is the easiest metal to machine and is also the lightest alloy commonly die cast.
• Lead and tin – it is used for special methods of corrosion resistance, and has a high density.
  They are not used everywhere, especially in food service.

What Are The Benefits Of Die Cast Engine?

Die cast engine has several benefits to it and this include;

• It has a long service life and this means it does not wear easily.
• It is a very cost effective and efficient process that offers a wider range of shapes and components.
• It is much stronger compared to the others like plastic injection.
• It offers a higher production rate with little to no machining.
• It offers smoother surfaces compared to other casting processes like sand.
• They can be produced with thinner walls than those from the other forms of casting.

What Are The limitations Of Die Cast Engine Block?

Some of the limitations of die cast engine include;

• It is quite expensive compared to the other processes.
• This process does not allow for large parts to be casted.
• Some gases may be entrapped in the form of porosity.
• It does not apply to alloys and metals that have high melting melting points.

What Does Die Cast Engine Block Involve?

Die cast engine block involve the following;

1. Clamping – clamping and preparation of the two die halves is the first step.
   To easen the ejection of the process that follows, each die half is cleaned first.
   The part size, number of cavities and side-cores are what determines the increase in lubrication time.
   Depending on the material, lubrication may not be needed after each cycle but after two or three cycles.
   The two die halves inside the die cast machine are locked and tied together after lubrication.
   A lot of force is needed to ensure it is tightly closed while metal is injected.
   The time needed to lock and brace the die is determined by the machine, the larger the machine the more time needed.

2. Injection – the molten metal is then moved to a chamber where it can be injected into the die after being kept at a certain temperature in the furnace.
   The molten metal is then poured into the die at high pressures after being transported.
   In the course of solidification, this pressure keeps the molten metal in the dies.
   The injection time is the amount of time it takes for the molten metal to fill all of the dies channels and cavities.
   In order to avoid early solidification of any one area of the metal, it is done over a very short period of time.
   Using the materials thermodynamic properties as well as the casting wall thickness the ideal injection time can be decided.
   A longer injection time is required for a thicker wall.

3. Cooling – When molten metal is poured into a die, it cools and solidifies as it enters the die cavity.
   The final shape of the casting is established when the entire cavity is filled and the liquid metal hardens.
   Until the casting has solidified and the cooling time has passed the die cannot be opened.
   The maximum wall thickness of the casting, and the complexity of the die can all be used to predict the cooling time.
   A longer cooling period can be achieved by having a thicker wall.
   Due to the greater resistance to the flow of heat the geometric setting of the die also requires a longer cooling time.

4. Ejection – The die halves can be opened, and the casting can be pushed out of the die chamber by an ejection mechanism after the set cooling period has elapsed.
   Because the part shrinks and sticks to the die during cooling, the ejection mechanism must apply some force to expel it.
   The die can be shut for the next injection after the casting is extracted.

5. Trimming – The material in the die’s channels will harden and become connected to the casting as it cools.
   This surplus material, as well as any flash, must be manually removed from the casting, either by cutting or sawing, or by utilizing a trimming press.
   The size of the casting’s envelope can be used to estimate the time required to trim the excess material.
   The scrap material generated by this trimming is either destroyed or recycled into the die casting process.

How Does Die Casting Engine Block Compare To Sand Casting Engine Block?

Casting is a process that entails pouring molten metal into a mold where the metal solidifies and conforms to the molds shape after it has cooled.

Die casting is a very detailed casting form where metals that can be reused are filled with liquid metal under pressure to create tight tolerance and highly accurate parts.

Sand casting is a process in which sand is used to create the casting molds for parts.

A pattern is made out of some compatible material which is in the shape of the final exterior of the product.

Die casting engine block

Both die casting engine block and sand casting engine block are widespread, efficient and very useful casting methods.

Sand casting is not as expensive compared to die casting which is quite expensive.

Die casting allows for mass production of products compared to sand casting which is mostly used to produce a small number of products.

sand casting engine block

Many defects arise from the sand casting process compared to die casting which has little to no defects.

Which Geometrical Features Should You Consider When Die Casting Engine Block?

When die casting engine block these are the geometrical features you should consider;

• Flash formation and location – an extension of metal can form on the casting or where separate die parts cast a feature at the parting line of the two die halves.
• Wall thickness – ensuring there are the same design walls throughout the part and where there are variations ensures a smooth metal flow during filling and reduces distortion caused from cooling and shrinkage.
• Ribs, metal savers and external corners – adding ribs on thin walls is important when designing a part.
  They add stiffness and strength to make a very solid part.
• Proper draft – draft prevents the casting from getting trapped in the tool during the ejection of the casting.
• Parting line – deciding on a type of parting line is among the most important factors. Designs with a straight parting line are the best since they are not as expensive when it comes to tooling costs.
• Radii and fillet – using radii and fillet increases structural integrity and also reduces the concentration of heat in the die and the part.

What Causes Die Wear When Die Casting Engine Block?

Most die wear is caused by heat checking.

This happens when thermal fatigue is caused by the alternating heating and cooling of the die surface.

Eventually small cracks form a closed network and become so large.

Which Defects Are Common In Die Cast Engine Blocks?

The most common defects in die casting engine blocks are misruns and cold shuts which are caused by low metal temperature.

Also, too much lubricant, metal that are not clean, and cold dies.

We have other defects such as;

1. Hot tearing. This is caused by a cooling rate that is not uniform.
2. Unfilled sections, which is caused by slow injection, insufficient shot volume and low pouring temperature.
3. Bubbles are caused by a non uniform cooling rate and too high injection temperature.
4. Ejector marks, this is caused by too high ejection force and a short cooling time.
5. Flash is caused by too low clamp force and too high injection pressure.

Which Techniques Can You Use For Die Cast Engine Blocks?

Sand casting process, here the molds and the cores can only be used once.

Gravity die casting – under the influence of gravity, the permanent mold casting steps makes use of a permanent steel die into which the aluminium melt is poured.

High pressure die casting – this process is characterized by high productivity.

Low pressure die casting – this is characterized by slow mould filling and solidification under pressure.

Squeeze casting – this is done in a vertical movement and it is done slowly.

Lost foam process – this allows the realization of very complex geometries while cast-in liners, additional chilling and porosity problems are not yet solved issues.

For any questions or inquiry on die casting engine block, contact us now.