Requirements for integrated die-casting for die-casting molds

Foshan City Yuwei Aluminum Products Co.,Ltd.

February 08, 2022

Integrated die casting requires higher strength and toughness of the mold. It requires impact resistance, tempering stability, good thermal conductivity, fatigue resistance, low thermal expansion coefficient, and high temperature oxidation resistance. High-speed filling and solidification are required in die casting, with higher demands on mold temperature, vacuum degree, forming scheme, process parameters, and post-processing requirements. Integrated die casting requires large molds, which are more complex and difficult to design. The mold design needs to include exhaust and slag collection systems, and CAE simulation technology is used to simulate the filling process. Poor exhaust can cause porosity in the parts. After die casting, the dimensions of the parts will shrink during cooling. Accurate simulation of the cooling process of the casting is needed, and shrinkage risers are set at the final cooling position to avoid the occurrence of hot spots. Otherwise, shrinkage, looseness, and crack defects may occur during the cooling and shrinkage process of the parts. Mold design manufacturers must have the ability to simulate and analyze the filling process of die casting. There are only a few domestic enterprises that can produce integrated die casting molds, such as Guangzhou Mold & Die, Ningbo Zhenzhi, and Sevada. A set of molds can support an annual capacity of 60,000 to 80,000 sets, with a unit price of nearly 10 million yuan. The first set of 6800t super-large integrated aluminum alloy die casting molds in China was successfully trial-produced by Hongtu Technology. The molds were independently developed by Guangzhou Mold & Die, with a weight exceeding 140 tons. Guangdong Hongtu's automotive chassis integrated structural parts are made of self-developed high-strength and tough heat-treated aluminum alloy materials. The dimensions of the castings are approximately 1.7m×1.5m×0.7m, and the casting weight is about 100kg. It is one of the largest aluminum alloy high-strength and toughness die castings currently available.

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