Pressure die casting is great for manufacturing higher volumes of metal parts in aluminium, zinc or magnesium. zhongmei-tech manufactures high quality die cast tools, offer precision die casting and post process machining and finishing options.
How It Works – Similar to injection molding but for metals, a mold tool is first manufactured by zhongmei-tech’s highly skilled toolmakers and engineers. This is then installed on a die casting press and molten metal is injected under pressure into the tool cavity. The parts can then be finished in a range of ways including powder coating and anodizing.
Hot Chamber Die Casting
Also known as gooseneck casting, hot chamber is the most popular die casting process. A chamber of the injection mechanism is immersed in molten metal and a “gooseneck” metal feed system brings the metal into the die cavity.
Cold Chamber Die Casting
Cold chamber die casting is often used to minimize machine corrosion. The molten metal is ladled into the injection system directly, eliminating the need for the injection mechanism to be immersed in the molten metal.
Magnesium alloys, as the lightest structural alloys having a density about one-fourth that of steels, offer significant potential for improving energy efficiency of various transportation systems such as automobiles1,2. Numerous R&D efforts in the last decade have led to the development of various types of magnesium alloys having good combination of strength and ductility3,4 and excellent corrosion resistance5. Although there are many variants of magnesium alloys showing large ductility, however, they usually show poor formability at room temperature3, hindering their widespread applications in automobiles. Poor formability of magnesium alloys arises from several factors; development of strong basal texture during rolling (thermomechanical treatment) and limited number of available deformation modes due to magnesium having hexagonal close-packed (hcp) structure6. Although Mg alloys are readily formable at warm or high temperatures despite their poor formability at room temperature, forming at warm or high temperatures is quite energy intensive and inefficient. Therefore, to make Mg alloys attractive for applications in automobiles, their formability at room temperature should be improved. There have been numerous attempts to improve formability of magnesium alloys and it has been shown that the formability of Mg alloys can be improved by texture randomization/weakening from the typical strong basal texture of conventional Mg alloys, which is usually achieved by the modification of thermomechanical processing7,8 and the addition of rare earth elements (REEs)9,10,11. The randomized/weakened basal texture of REE-containing alloys is certainly beneficial for formability, but also results in low strength. Such inverse relationship between formability and strength is also applicable to other non-REE containing Mg alloys3. Figure 1 shows the Index Erichsen (IE) value (which is an indication of stretch formability; see Methods) as a function of yield strength of various Mg alloys3,8,12,13,14,15,16. As shown in Fig. 1, yield strength of Mg alloys having the IE values larger than 8 mm is lower than ~160 MPa. However, as yield strength of Mg alloys increases to 200 MPa, their IE values become lower than 6 mm, making them non-formable at room temperature. It is apparent that the conventional approaches that improve formability have adverse effects on strength or vice versa. Therefore, new alloy design and processing concepts should be utilized to develop high strength Mg alloys with good formability at room temperature.
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