Automated Die Cast Plant

Premier invests in capital equipment to provide quality products in both high and low volumes. Our die cast plant has state of the art technology with automated Prince machines ranging from 450 to 1000 tons. The advantages of process consistency, precision, and reduced labor our Robots and Auto-ladles offer.

Process Monitoring and Closed Loop Control

Production errors are eliminated with our advanced technology: The Visi-Trak? System, monitoring the balance of the machines, and the "closed loop" cells, ensuring process consistency "shot-to-shot". The built-in process monitoring and self-adjusting capabilities of the Prince machine assure expeditious correction of any problems during operation. In addition to our first-rate automated machinery, our knowledgeable staff interfaces with the automation to react to detected problems and to inspect the product for deficiencies.

Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial and industrial products. Die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.

We continue to invest our efforts to fully satisfy our customers by providing excellent casting solutions that are innovative and compliant to international quality standards.

High pressure die casting is a process we use to make aluminum die cast parts. We inject molten aluminum alloy metal under pressure into a steel die to produce aluminum parts. Diecasting is a very inexpensive aluminum part manufacturing process

Primarily we produce aluminum alloy die castings, but we also make some diecastings in zinc alloys. Kinetic Die Casting Company\s die cast design consultants will assist you with die casting aluminum part design, aluminum die casting prototypes, die cast tooling, machining of die cast parts and finish the surface of many kinds of die cast aluminum parts

Surface treatment: shot blasting, sandblasting or spray painting as per customers requirements

Aluminum Die Casting, Aluminum Casting for virtually any finished good. If you manufacture it, we can supply the components. If you want it manufactured, we can provide the entire assembly, packaged and ready for your customer.

Die casting machine between 250kN to 1000kN. Aluminum casting cast from several grams to kilograms. Supply finish machining process when customer require.

Place a pattern in sand to create a mold. Incorporate a gating system. Remove the pattern. Fill the mold cavity with molten metal. Allow the metal to cool. Break away the sand mold and remove the casting.

A variety of heat treatments are available so that you can be assured of a quality product that will meet or exceed your expectations.

Please send your requirements to us and our experienced engineering staff will eliminate manufacturing problems and reduce cost.

Our customers trust and depend on Precision Casting for precision aluminum castings that are vital to their product lines.

Aluminum Precision Casting, forgings, weldment fabrications are frequently converted to aluminum castings to reduce cost.

The mold is made by making a pattern using wax or some other material that can be melted away. This wax pattern is dipped in refractory slurry, which coats the wax pattern and forms a skin. This is dried and the process of dipping in the slurry and drying is repeated until a robust thickness is achieved. After this, the entire pattern is placed in an oven and the wax is melted away. This leads to a mold that can be filled with the molten metal. Because the mold is formed around a one-piece pattern, (which does not have to be pulled out from the mold as in a traditional sand casting process), very intricate parts and undercuts can be made. The wax pattern itself is made by duplicating using a stereo lithography or similar model-which has been fabricated using a computer solid model master. investment casting, investment castings, casting, carbon steel casting

patterns

The cavity in the sand is formed by using a pattern (an approximate duplicate of the real part), which are typically made out of wood, sometimes metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape inserted into the mold to produce the internal features of the part such as holes or internal passages. Cores are placed in the cavity to form holes of the desired shapes. Core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold. A riser is an extra void created in the mold to contain excessive molten material. The purpose of this is feed the molten metal to the mold cavity as the molten metal solidifies and shrinks, and thereby prevents voids in the main casting. sand casting, cast iron casting, aluminum sand casting, grey iron casting, ductile iron casting

Option for Green Sand Casting

green sand molds are composed of a particulate or granular material, typically sand, which is held together with a binder such as a mixture of clay and water. These molds may be manufactured rapidly for simple molds in an automated mold making plant.

Green sand molding

2. Such resin-bonded sand molds take somewhat longer to manufacture than green sand molds because a curing reaction must take place for the binder to become effective and allow formation of the mold.

3. As in clay-bonded molds, the sand can often be recycled, although with some treatment to remove the resin.

Iron Casting are a family of ferrous metals with a wide range of properties produced by being cast into shape as opposed by being formed,other elements are used to control specific properties, cast irons have a wide range of mechanical properties which make them suitable for use in engineering components. The wide spread use of cast iron is as a result of its low cost and versatile properties.

Ductile iron casting has a clear advantage over malleable iron for applications where low solidification shrinkage is needed or where the section is too thick to permit uniform solidification as white iron

Roughing

This is the first stage of machining where the object is to quickly remove the bulk of the waste material, normallywith the aid of a ripper cutter (see cutters below), this gives the coarse stepped feature seen in the workpiece above. CNC machining, CNC machinings

Semi Roughing

This stage of machining generally uses a smaller cutter than roughing, typically an end mill, although the aim is still to remove the bulk of the waste material.

High-speed production - Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.

3) Precision machining: CNC lathes, milling, drilling, grinding, etc.

4) Surface finish: Chrome plating, sandblasting, painting, anodizing, powder coating, electrophoresis

5) Applied software for specification drawings: Pro/E, Auto CAD, Solid Work; CAXA, UG, CAD/CAM/CAE

6) Detailed products range: Auto parts, motor shell, pump parts, machinery parts, Lamp chimney, other parts for home products

2) Product weight from 0.02kg to 5kgs

3) Process: Die Casting + Machining

4) Secondary Machining: CNC turning, milling, drilling, grinding, assembly to packing

5) Surface Finish: Chrome plating, Zinc Plating, Sandblasting, Powder Coating...

6) OEM/ODM parts range: Auto parts, electronic parts, motor shell, pump parts, machinery parts, light fittings, dental equipment, medical cases etc and other industrial uses

7) Applied software for specification drawings: Pro/E, auto CAD, solid work, CAXA, UG, CAD/CAM/CAE

8) Products shown on the website are OEM/ODM produced; For reference use only

Pacific Casting manufactures Aluminum Die Casting, Aluminum Casting for virtually any finished good. If you manufacture it, we can supply the components. If you want it manufactured, we can provide the entire assembly, packaged and ready for your customer.

Pacific Casting manufactures Aluminum Die Casting, Aluminum Casting for virtually any finished good. If you manufacture it, we can supply the components. If you want it manufactured, we can provide the entire assembly, packaged and ready for your customer.

Pacific Casting manufactures Aluminum Die Casting, Aluminum Casting for virtually any finished good. If you manufacture it, we can supply the components. If you want it manufactured, we can provide the entire assembly, packaged and ready for your customer.

2) Standard: JIS,ASTM

3) Weight :0.005-100kg

4) Process :Investment casting ,sand casting

5) Manufacturing equipment : middle -frequency electrical furnace, wax injection press, peening machine, shot-blasting machine , heat treatment furance , argon arc welder , plasma cutting machine, running balance indicating machine , CNC lathes,common lathes, drilling Machines , milling machines, radial drilling machines, dehumidifier and so on .

6) Testing machine : spectrograph, magnetic powder inspection machine , supersonic reflectoscope, Rockwell apparatus ,Brinell hardness tester ,metaloscope, tensile testing machine , universal tester .

Material: Ductile cast iron

Weight: 0.3kg to 100kgs

Process line: EPC

Certificate: ISO2000

2) Standard: JIS, DIN, ASTM, BS

3) Weight: 0.1 - 500kg

4) Process: sand casting, investment casting, die casting, permanent mold casting

2) Standard: JIS, DIN, ASTM, BS 3) Weight: 0.1 - 5000kg 4) Process: investment casting,5) We can make products to your exact specifications from our optimized processes6) Very rigorous quality control

Packing: wooden cases or according to customers' needs

Various high quality castings are made of gray iron, ductile iron, aluminum, steel, brass etc. Quality control checks are performed throughout the casting process form screening the raw material for stability the concentration of alloy and melted by the electric furnace. We analyze the chemical elements concentration of the alloy with spark spectrometer testing before castingAfter casting and heat treatment we continue testing by metallurgical microstructure analysis, as well as checking tensile, impact strength and surface hardness by physical test and magnetic particle etc.

Customer s drawing Technological design Pattern making Molding Melting Pouring Sand blasting Dressing Pre-inspection Heat treatment Final inspection packing shipping

Various high quality castings are made of gray iron, ductile iron, aluminum, steel, brass etc. Quality control checks are performed throughout the casting process form screening the raw material for stability the concentration of alloy and melted by the electric furnace. We analyze the chemical elements concentration of the alloy with spark spectrometer testing before castingAfter casting and heat treatment we continue testing by metallurgical microstructure analysis, as well as checking tensile, impact strength and surface hardness by physical test and magnetic particle etc

Producing capability including andirons, exhaust manifolds, frames, grates, housings, machine bases, manhole covers, air-cooled cylinders, clutch housings, clutch plates, compressor frames, cylinder heads, flywheels, gearboxes, grate bars, impellers, light-duty brake drums, oil pump bodies, pipe and fittings,rams small cylinder blocks, and transmission cases

Although this is the final machining stage there is still much work to do in the form of hand polishing and finishing before the article is complete

The cast iron heat treatment process:

1. Annealing elimination of stress due to uneven casting thickness, heating, cooling and phase transition process will produce stress and stress. Also in large parts of its processed within easy residual stress, all of which are necessary to eliminate stress. Annealing is usually to stress the heating temperature of 500 550 lding time for 2 8 h, and then furnace cold (gray iron) or air-cooled (ductile iron). Using this technology can eliminate the stress of casting 90 to 95 percent, but the cast iron organization does not change. If the temperature exceeds 550 holding time is too long, it will cause graphite, to reduce the casting strength and hardness.

2. Elimination of the high-temperature casting white graphite annealing casting cooling, surface and thin cross sections, often produce white. White hard and brittle organizations, poor processing performance, easily peeling off. Annealing to be used (or normalizing) approach to the fight against white organizations. Annealing Process: heated to 550-950sulation 2 5 h, then cold to furnace 500-550 air-cooled. In high-temperature insulation, high outbound cementite and eutectic cementite divided into graphite and A, in the subsequent cooling process for the second cementite and eutectoid cementite also decomposition, in the process of graphite. As cementite of decomposition, resulting in hardness decline, thereby enhancing the cutting of.

3. Ductile iron is the iron fireballs normalizing the purpose is to be pearlite matrix organization, and refined grains, uniform organizations, to enhance the mechanical properties of casting. Sometimes the ball is normalizing iron surface hardening in the organization of preparation, normalizing at low temperature and high temperature normalizing normalizing. High-temperature normalizing temperature generally no more than 950 980 ow-temperature heat to a total of normalizing the general presentation of the temperature range 820 860 fter normalizing for the general need to deal with four to eliminate at normalizing the stress.

4.a certain validity of the stability and flexibility in thick pieces. High-temperature tempering temperature of 500-60 D ter tempering tempering Soxhlet for organizations to increase spherical graphite, a good combination of strength and toughness of the comprehensive performance, wide application in production.

5. Ball and the use of multi-quenching ductile iron, such as the temperature can be quenched high-intensity, and both plastic and good toughness. Multi-quenching heating temperature of the main consideration so that the original choice of organizations of all A, non-residual F, but also to avoid A grain growth. The general Afc1 heating temperature above 30 50 uch as temperature temperature of 0 350 ensure access to a comprehensive mechanical properties of the bainite organizations. Mg-Al-iron, and other rare earth temperature quenched 1200 1400MPa, 3 3.6J/cm2, HRC 47 51. It should be noted, such as temperature quenched with a tempering process.

6. Hardening the surface of certain items in order to improve the surface hardness, wear resistance and fatigue strength, the surface can be quenched. Ductile iron and gray iron castings to the surface can be quenched. The general high (in) frequency induction heating and hardening the surface, hardening the surface contact.

7. Chemical heat treatment requirements for wear-resistant surface or anti-oxidation, corrosion resistance of the castings, steel can be used similar to the chemical heat treatment process, such as soft chloride gas, chloride, boronizing, seepage, such as sulfur treatment.

Since the casting mold in cooling pouring out after a gate, riser and metal spikes Phi slit, sand casting of the casting also adhesion of the sand, it must be clean-up process. Such devices are the work of the Blasting machine, gate riser cutting machines. Sand-casting sand clean-up is a poor working conditions processes, in the choice of modeling methods, should be taken into account for as much as possible with sand to create convenient conditions for clean-up. Casting a result of some special requirements, but also by casting post-processing, such as heat treatment, plastic surgery, anti-rust treatment, such as rough.

Casting is more economic methods of rough shape, the shape of more complex components demonstrated its economy. aluminum die casting Such as car engine block and cylinder head, ship propellers and exquisite works of art, and so on. Cutting some of the difficult parts, such as the combustion turbine parts do not have to nickel-based alloys casting method can not be forming.

In addition, the die casting of parts of the size and weight to a wide range of metal types of almost unlimited; parts in a general mechanical properties, it is also a wear and corrosion-resistant, shock-absorbing properties, and so is the other metal forming methods such as forging , Rolling, welding, salt, and so can not. Therefore, in casting machine manufacturing methods used in the production of rough parts, and the number is still on the tonnage is the largest. Casting often use a variety of metal materials, coke, wood, plastic, gas and liquid fuels, such as modeling materials. Have the necessary equipment used in various metal smelting furnace, a Mixer with the various Mixer, a shape-made batteries used in various molding machine, machine-made batteries, cleaning up the castings used for loading sand, Shot Blasting Machine And so on. Casting is also available for special machinery and equipment, and many transportation and material handling equipment.

Casting and other technology have different characteristics, mainly wide adaptability, needed materials and equipment, pollution of the environment. Casting will have dust and harmful gases and noise pollution to the environment, compared to other machinery manufacturing processes to become more serious, need to take measures to control.

Casting product development requirements of the trend is casting a better overall performance, higher accuracy and less headroom and clean the surface. In addition, the requirements of energy-saving society and restore the natural environment of the call also getting higher and higher. To meet these requirements, the new cast alloy will be developed, the new smelting technology and new equipment will be corresponding.

Casting the mechanized production continuously improve the degree of automation in the same time, to be more flexible production development, to expand the volume and variety of different production adaptability. Conserve energy and raw materials of new technologies will be giving priority to the development, have little or no pollution of the new equipment, new technology will be the first attention. Quality control technology in all stages of testing and nondestructive testing, stress determination, there will be a new development

The process is generally used for small castings, but has produced complete aircraft door frames, steel castings of up to 300 kg and aluminium castings of up to 30 kg. It is generally more expensive than die casting or sand casting, but can produce complicated shapes that require little rework or machining.

Investment casting offers high production rates, particularly for small or highly complex components, and extremely good surface finish (CT4-CT6 class accuracy and Ra1.6-6.3 surface roughness) with very little machining. The drawbacks include the specialized equipment, costly refractories and binders, many operations to make a mould, and occasional minute defects.

Investment casting is used in the aerospace and power generation industries to produce single-crystal turbine blades, which have more creep resistance than equiaxed castings. It is also widely used by Sturm, Ruger among other firearms manufacturers to fabricate firearm receivers, triggers, hammers, and other precision parts at low cost. Other industries that use standard investment-cast parts include military, medical, commercial and automotive.

Die-casting can be done using a cold chamber or   hot chamber process

1.In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures.

2.In a hot chamber process the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures.

Die casting molds (called dies in the industry) tend to be expensive as they are made from hardened steel-also the cycle time for building these tend to be long. Also the stronger and harder metals such as iron and steel cannot be die-cast

Common Alloys in Die Casting

Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. On the other hand, pure Aluminum is rarely cast due to high shrinkage, and susceptibility to hot cracking. It is alloyed with Silicon, which increases melt fluidity, reduces machinability. Copper is another alloying element, which increases hardness, reduces ductility, and reduces corrosion resistance.

Aluminum is cast at a temperature of 650 (1200 oF). It is alloyed with Silicon 9% and Copper about 3.5% to form the Aluminum Association 380 alloy (UNS A03800). Silicon increases the melt fluidity, reduces machinability, Copper increases hardness and reduces the ductility. By greatly reducing the amount of Copper (less than 0.6%) the chemical resistance is improved; thus, AA 360 (UNS A03600) is formulated for use in marine environments. A high silicon alloy is used in automotive engines for cylinder castings, AA 390 (UNS A03900) with 17% Silicon for high wear resistance. Common aluminum alloys for die casting are summarized as follows:

Zinc can be made to close tolerances and with thinner walls than Aluminum die casting, due to its high melt fluidity. Zinc is alloyed with Aluminum (4%), which adds strength and hardness. The casting is done at a fairly low temperature of 425 (800 oF) so the part does not have to cool much before it can be ejected from the die. This, in combination with the fact that Zinc can be run using a hot chamber process allows for a fast fill, fast cooling (and ejection) and a short cycle time. Zinc alloys are used in making precision parts such as sprockets, gears, and connector housings.

Copper alloys are used in plumbing, electrical and marine applications where corrosion and wear resistance is important.

Minimum wall thicknesses and minimum draft angles for die casting are :

Die-castings are typically limited from 20 kg (55 lb) max. for Magnesium, to 35 kg (77 lb) max. for Zinc. Large castings tend to have greater porosity problems, due to entrapped air, and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. The porosity problem can be somewhat overcome by vacuum die casting

From a design point of view, it is best to design parts with uniform wall thicknesses and cores of simple shapes. Heavy sections cause cooling problems, trapped gases causing porosity. All corners should be radiused generously to avoid stress concentration. Draft allowance should be provided to all for releasing the parts-these are typically 0.25o to 0.75o per side depending on the material.