Hot Chamber Die Casting

Inox Hot Chamber Die Casting

Inox Cast is well-experienced in the whole process of hot chamber die casting. Through this method, we can produce different metal parts with the best quality features.  While using the finished metal parts from hot chamber die casting, you will surely the best outcome for your ideal applications.

Commonly, hot chamber die casting is the best process of molding magnesium alloys materials. The machines also used for the hot chamber die casting method are mainly applied for copper, zinc alloys, lead, and so on.

Inox has many years of experience in helping with low melting point alloys. This also doesn`t willingly erode and attack metal cylinders, plungers, and pots.

Preferring the hot chamber die casting method will help us create good-quality, more durable finished products.

However, finished products from using the hot chamber die casting method is used in diverse applications. It is used to produce the best metal parts for automotive machines, agriculture machines, pump and valve systems, transportation equipment, and construction machine.

While keeping production process quality planning, design, final quality control in-house, and design, we can fully attain your satisfaction and trust, since that is the core of our business. We are keeping on mastering our efficiency in order to provide quality assembled mechanical parts.

To achieve the customers` different functional and mechanical requirements, we offer a huge range of metal products in support of blanks technologies and solutions.

If ever you have a project that needs low melting point alloys, Inox may be able to assist. You are very welcome to give your technical inquiries.

Hot Chamber Die Casting: The Ultimate FAQ Guide

This is a complete guide to hot chamber die casting.

So, if you have any question about hot chamber die casting, you will find the answer right here.

Keep reading to learn more.

What Is Hot Chamber Dies Casting?

This is a manufacturing process of a permanent mold that uses huge volumes of pressure that is used in the pushing of molten metals through a mold.

Castings produced with this specific type of manufacturing process usually great final products that are of a dimensional accuracy that is accurate, a good surface detail and very thin walls.

What Are The Advantages Of Hot Chamber Die Casting Process?

The following are some of the advantages of the process;

In this manufacturing process, in terms of time, it has a cycle time that is faster thus allowing the companies to make more products within a short while hence improving productivity.

With this manufacturing process, there is reduced porosity.

Machinery used in this type of process has a longer life because the metals used during the process are only of low melting points.

The process has high levels of efficiency as the machine has melting pot that is built internally.

Since there is close to minimal when it comes it metal loss or waste, the manufacturing process is considered to be friendly to the environment.

Figure 1- re The Disadvantages Of Hot Chamber Die Casting?

Below are the disadvantages of the hot chamber die casting process;

When it comes to cost, the process requires high levels of initial finances that are required in the setting of the machine and other equipment essential for the process.

The process also cannot be heat treated fully as it leads to blister formation on the surfaces of the metal.

Also, the process is only applicable when it comes to the casting of metals with melting points that are low like the alloys of magnesium and zinc thus higher melting point metals cannot be cast using this process.

To have the process done, you need very high pressures which are not ideal in the making of most of the products.

The process also offers metal fluidity that is limited because of the variances in the malleability of alloys thus it will limit the complexion and shape of the final outcome of the product.

Moreover, this process becomes cost-effective when you want to produce a large volume of products.

How Does How Chamber Die Casting Compare To Cold Chamber Die Casting Process?

Figure 2-An Illustration Of The Cold Chamber Process

When it comes to the cold chamber die casting process, the following is what occurs;

To start with, this is a manufacturing process that entails heating the metal to acquire its molten state in a furnace that is separate.

Thereafter, the acquired molten metal is then transferred and fed into the chamber of the casting machine.

To ensure that the molten metal has gone into mold’s cavity, a plunger that is pressurized is used by the machine.

It is important to note that the manufacturing process is applied to metals that have higher melting points as compared to the hot chamber process of die casting that involves metals with low melting points.

For this kind of process, it requires a furnace that is situated on the outside and a ladle which is used to when it comes to the pouring of the metal which is molten.

Compared to the hot chamber die casting process, this process has worked the corrosion problems as it separates the injector components from the melt pot.

Benefits Of Cold Chamber Die Casting Process

Here are the benefits witnessed when this kind of process has been employed;

There Are High Accuracy Levels And Stability

Parts being produced with this type of process promise durability and they are also stable.

At the same time, resistance to heat and close tolerances are maintained.

Speedy Productions

Compared to the other process of mass production, this specific process of production has the ability to produce shapes that are complex within a short while of time while maintaining tolerances that are close.

Many castings that are identical can be produced within a very short period before any tooling is considered.

There Is Improved Strength And Increased Weight

With this type of casting, it is evident that is stronger as compared to the other injection moldings of plastic having the same size.

Even in thin wall casting, the walls are very much strong as compared to the same sizes of walls in the hot chamber die casting and other types of castings.

These walls are not only stronger but also they are lighter.

Most importantly, this strength emanates from the alloy itself as the when it comes to die casting, there is no part fastening needed or welding that is needed.

Finishing Techniques

Parts in this process can be produced either with textured or smooth type types of surface finishes, this is because the parts are easily plated and finished with a preparation of the surface that is minimal.

Assembly That Is Simplified

The process provides elements of fasting which are integral like the use of studs and bosses.

Often, holes can be drilled and cored or casting of external threads can take place.

Disadvantages Of Cold Chamber Die Casting Process

The cycle of production in this process takes longer when related to the hot chamber die casting process.

Also, the process is longer since the metal which has been melted in the separate chamber may cool down before having the injection done.

The process has high oxidation levels and other contaminants thus it may impact the final product in a negative way.

Which Components Make Hot Chamber Die Casting Machine?

The following are the components making up the hot chamber die casting machine;

Injection mechanism

The injection mechanism of the hot chamber die casting machine has a furnace that is used in heating and melting the metal.

It also consists of the chamber that is used in the storage of the metal which has been molten initially in the furnace.

The chamber is usually linked to the machine using a metal tube known as the gooseneck.

Die

This is the mold that should now get filled with a metal thus it gives the final product it6s shape as the molten metal is going to take its shape.

Plunger and piston

The piston at this point functions by raising itself thus giving way and letting the metal get into the die.

Again, the pot now is going to get sealed by the plunger and the metal fills the die.

The position is held until the metal solidifies itself.

Ejector pins

The die now opens when the metal has solidified and the plunger allows any remaining metal that is molten to get back into the chamber.

Moreover, the function of the ejector pins is the removal of objects from the die.

Components Of Hot Chamber Die Casting  Machine

How Does How Chamber Die Casting Process Work?

The process uses the hot chamber die casting machine which comprises a melting pot which is inside the casting machine.

As discussed earlier, metals used in this type of process are metals with melting points that are lower as the likes of zinc, tin, and magnesium.

The supply of these low melting point metals is connected to the machine.

Here is the actual process of how the hot chamber die casting works;

Injection

The molten metal is filled into the hot chamber.

The plunger is usually raised at this point and the mold is filled with the metal.

Sealing Of Chamber

At this point, the plunger starts moving downward thus forcing the metal into the mold’s cavity and it is sealed the moment it is filled.

Cooling

After sealing of the mold has taken place, it is now left to cool and the solidification of the metal now takes place thus the metal takes the shape of the mold.

Ejection

After the solidification process of the metal, the die then opens and the cooled metal is ejected hence the mold is prepared for the next cycle.

Which Materials Can You Cast Using Hot Chamber Die Casting?

Materials to be used in this process should be materials that have melting points that are lower.

So that they will not erode or dissolve the metal of the machine in the event they are subjected to high temperatures or pressure.

For instance, a part like the plunger is endlessly sunken in the molten metals, if the metals have a greater melting point; the plunger will be damaged thus compromising how it functions.

The best materials to use for the hot chamber die casting include materials such as tin, magnesium, and zinc.

Zinc

Zinc and alloys made from it do offer high quality of strength and hardness thus making it to be applicable in many applications.

It also serves as a good substitute for machined, pressed, and fabricated components.

In addition, it offers excellent electrical conductivity, great thermal conductivity, corrosion resistance and it’s affordable amongst other advantages.

Magnesium

This is a lightweight metal that is strong thus making it get used in many applications.

Some of its advantages include the following; its thermal conductivity is excellent, it has great electrical conductivity, its finishing characteristics are excellent, it is resistant to environmental corrosion and it is recyclable.

Does Hot Chamber Die Casting Have Minimum Part Thickness?

Yes, there is a minimum part thickness in the hot chamber die casting.

In this manufacturing process, the minimum part thickness is 0.02 inches.

Which Defects Are Common During Hot Chamber Die Casting Process?

The common likely defects during this die casting process are as follows;

Blisters

Blisters Are A Type Of Die Casting Defect

With this type of defect, a film that is thin on the surface blows upon the component’s surface.

The bubble forming is always hollow in nature.

It is normally caused by the following conditions;

In the event there are high temperatures of the die, blisters are going to appear on the surface of the component.

When the die coat is sprayed improperly on the tool or it is low, blisters are also likely to occur.

The tool’s cooling jam is fixed on the sides or moved on the side.

Here are some of the remedies to prevent blisters from appearing on the surfaces of components;

There should be checking and opening of the chocked die cooling that will see the blisters being prevented from appearing.

The diet coat spray should be applied properly thus maintaining a good flow of the spray.

You need to have a good ratio mix of the reverse osmosis water and the chemical of the die coat to hence bubble are going to be prevented.

The die opening time band the time of continuation cycle should be regularly checked and maintained to prevent blister formation.

Blow Holes

Blowholes appear in the scenario the metal has trapped some gas during the process of casting.

When the molten metal has fully cooled and solidification has taken place, bubbles structure since the metal is unable to hold much gas as when it was in the fluid form.

The pockets of air usually show up on the surface as circular cavities or at times holes in the casting.

Their causes include the following;

• The moment some steam has been trapped in the die coat, the blowholes will show.
• High volumes of the die coat spray when applied lead to the occurrence of blowholes.
• Improper venting also leads to the formation of circular cavities and holes in the casting.

Remedies to bow holes

• There should be appropriate ventilation.
• The spraying of the die coat should be appropriate, meaning that it should not be low or high but the required amount.
• A proper die coat mixture should be made.

A Blow Hole In A Die-Cast Material

Weight Less

This is the situation where the final cast outcome weight is less as compared to the standard normal weight of the casting.

As a result of this, the strength is highly compromised as it is reduced, and, it may 7 fail a lot of quality tests that determine its functionality.

Below are some of the causes of weightless;

• Weightless occurs when the mold cavity has not been filled well with the molten metal.
• When there are melting runners inside the furnace.
• Molten metal passes through the plungers since their rings are worn out.

Remedies to weigh less;

• Ingots are the only ones to be melted since runners entail impurities.
• Rings of the plunger bought to be checked and replaced when they are worn out to prevent the molten metal to reach the mold cavity hence weightless will not be there.
• The injection pressure and the main oil pressure should be checked and maintained to ensure that they are functioning in the desired manner.

At What Temperature Is Hot Chamber Die Casting Process Recommended?

For the thicker die casting, a temperature of about 160 °C is recommended.

For the thinner die casting, a temperature of about 245 °C is recommended.

How Do You Increase Efficiency During Hot Chamber Die Casting Process?

The following are some of the ways that efficiency can be improved in this type of manufacturing process.

Reduction Of Weight

The main motive here is to meaningfully slash down the metal volume for the components as it will help the manufacturers to save on the costs and save weight during the process of die casting.

If the components used during the die casting do contain much metal, they are going to take a huge time to fill the die cavity and for cooling just before the ejection.

Addition Of Ribs

The die casting manufacturers usually add ribs on the die casts that are thin-walled so as to have their levels of strength increased.

These ribs are added at specific locations in order to ensure that the desired strength levels results are achieved.

Moreover, the added ribs have fillets that are used in suppressing of the rapid changes which might occur on the component’s cross-section.

Draft

While die casting, the metal will always shrink as a result of the process thus allowing the casting to escape from the cavity.

The draft should be applied to the die casting component to reduce the shrinkage from taking place.

Having Cross Sections That Are Uniform

It is important for the die casters to ensure that their components cross-sections are uniform as it is going to guarantee a smooth flow of the metal into the die.

Uniformity in the cross-sections should be considered as sudden changes in the thickness of walls causes turbulences in the metal because the cross-sections lack uniformity.

How Do You Choose Best Machine For Hot Chamber Die Casting?

The best machine for the hot chamber die casting is chosen by considering the following;

Firstly, the machine should be tested and be able to function as intended in terms of its own efficiency and productivity.

Some of the critical parts to consider the machine include the following;

Ton Capacity

Depending on the type and the level of task you want the machine to perform, you need to choose the right ton which will serve your purpose.

Base Of The Machine

This is the point where the structure of the machine rests.

Therefore, the base of the machine should have a structural base that is strong to support the machine.

Heat Exchange System

You need to choose a machine that has been tested that is having a good functioning cooling system that is going to be used when cooling down the system when overheating.

Die Locking Mechanism

The die locking system should be one that is adjustable for it to hold the different types of dies.

Hydraulic System

Since it is the most responsible to make sure that there is a good movement among the components, it should be checked before choosing the machine and settling on a machine.

Always Consider The Above Critical Things When Selecting A Hot Die Casting Machine

How Does Hot Chamber Die Casting Compare High-Pressure Die Casting?

The hot chamber die casting employs the use of high pressure that makes molten metals go through a mold.

In the high-pressure die casting, the molten metal is also pushed under high pressure into a mold cavity that is sealed.

While in the mold, the molten metal is held in place with compressive powers that are strong until solidification takes place.

When Should You Choose Hot Chamber Die Casting As Opposed To Other Types Of Die Casting?

The hot chamber die casting should be chosen over the other die casting methods at the time you want to die-cast metals that have a lower melting point.

How Can You Determine Cost Of Hot Chamber Die Casting?

The cost of the process is determined by the following factors;

• Cost in acquiring of raw materials and other components
• Mold costs
• Production costs of the entire process

Which Variable Determine Quality Of Hot Chamber Die Cast Parts Or Components?

The process is usually controlled by variables that determine the quality of the casted parts or components.

The main variables include;

• Dosage volume
• Pressure of injection
• Mold temperature
• Chemical composition
• Slow and fast shots

Is Hot Chamber Die Casting Suitable For Precision Die Casting Process?

No, it is not.

What Is The Average Cycle Time Of Hot Chamber Die Casting Process?

The average cycle time of the hot chamber die casting process is about 15 to 20 minutes.

At What Pressure Do Hot Chamber Die Casting Work Best?

The die casting process works under a pressure of about 1000 to 5000 psi.

Is Hot Chamber Due Casting Suitable For High Volume Production And Complex Parts?

Yes, the process is suitable for high volume production and complex parts because of its higher speed cycling production.

The high volume production and complex parts are only applicable to metals with a lower melting point.

How Long Will Hot Chamber Die Casting Tool System Last?

The hot chamber dies casting tool system lasts longer since the melted metal’s temperature does not corrode the tool system.

The metals are usually of low melting points.

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