High Pressure Die Casting Tool And Die Making Service

Superalloy Equiaxed Crystal Casting Service produces components with a uniform, granular crystal structure, enhancing mechanical strength and durability. This method is ideal for turbine parts, including disks and wheels, used in high-temperature, high-stress environments like gas turbines.

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What Is Die Casting Tool And Die?

Aluminum die casting is a manufacturing process where molten aluminum is injected into a steel mold under high pressure. It creates durable, complex, and precise parts used in various industries, including automotive, aerospace, and electronics.

Steps	Description
Function	Die casting tools and dies are essential in shaping molten metal into precise, high-quality parts. They ensure accurate cavity dimensions, durability, and smooth part surfaces, making them vital for mass production in automotive, aerospace, and industrial sectors.
Male Mold	The male mold, also known as the "core" in die casting, is the part of the die that forms the inner features of the casting. It is typically positioned inside the female mold to create hollow sections or detailed features.
Female Mold	The female mold, or "die shell," is the external mold that encases the male mold. It provides the outer shape of the casting, and is essential in forming parts with complex geometries, ensuring smooth and uniform casting.
Mold Cavity	The mold cavity is the space formed between the male and female molds where the molten metal is injected. It determines the shape and dimensions of the final die-cast part, and must be designed precisely for high-quality production.

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Typical Materials of Tool and Die

Typical materials for tool and die-making include high-strength steels like H13, P20, D2, and A2, as well as Beryllium Copper and Tungsten Carbide. These materials offer excellent wear resistance, shock resistance, and high-temperature performance, making them ideal for creating durable molds and tools used in die casting, injection molding, and other manufacturing processes.

Tool Materials	Aliases	Tensile Strength (MPa)	Yield Strength (MPa)	Hardness (HRC)	Thermal Conductivity (W/m·K)	Density (g/cm³)	Applications
H13 Steel	1.2344 (EU), X40CrMoV5-1 (Germany)	1400-1700	1000-1300	45-50	27.3	7.8	General-purpose die casting, tool dies, hot working tools
P20 Steel	1.2311 (EU), DIN 1.2311 (Germany)	750-1000	500-700	28-32	24	7.8	Injection molds, plastic molds, die casting molds
D2 Steel	1.2379 (EU), X153CrMoV12 (Germany)	1600-1900	1200-1500	55-60	25	7.7	Wear-resistant dies, plastic and rubber molding
A2 Steel	1.2363 (EU), X100CrMoV5 (Germany)	1000-1300	850-1050	55-60	25	7.8	Cold working dies, punching, blanking, and stamping
Beryllium Copper	CuBe2 (US), UNS C17200 (US)	500-800	300-500	30-40	120-160	8.2	Mold inserts, die-casting cores, electrical components
Tool Steel S7	1.2714 (EU), X40CrMoV5-1 (Germany)	1400-1800	1200-1500	45-55	20	7.8	Shock-resisting dies, hot work, and die-casting molds
Tungsten Carbide	-	3000-4500	2500-4000	70-85	150	14.0	Molds for high-wear applications, mining, and die casting
Inconel 718	-	1300-1700	1100-1400	35-45	11.4	8.9	High-temperature die-casting, aerospace and turbine components

Typical Surface Treatment for Casting Tool and Die

Typical surface treatments for casting tools and dies include nitriding, PVD coating, electroplating, shot peening, polishing, and hard coating. These treatments enhance the hardness, wear resistance, corrosion resistance, and overall performance of the tool or die, ensuring better lifespan and reliability in demanding manufacturing processes.

Surface Treatment	Description	Purpose/Benefit	Applications
Nitriding	A heat treatment process that introduces nitrogen into the surface of the steel or alloy.	Improves wear resistance, fatigue strength, and corrosion resistance.	Tooling, dies, molds, aerospace, automotive, and high-performance machinery.
PVD Coating	A thin-film coating process that uses physical vapor deposition to apply a hard coating to the die surface.	Improves surface hardness, wear resistance, and provides a smooth finish.	Molds, forming tools, stamping dies, cutting tools, and precision tooling.
Electroplating (Nickel, Chrome, etc.)	Depositing a metallic coating on the die surface using electrochemical processes.	Enhances surface hardness, corrosion resistance, and aesthetic appearance.	Stamping tools, dies, industrial machinery, precision molds, automotive tools.
Shot Peening	A process of bombarding the die surface with small spherical media to create compressive stress.	Increases fatigue strength, enhances durability, and reduces cracking.	Molds, dies, aerospace, automotive parts, and precision tools.
Polishing	Mechanical or chemical process to smooth the surface of tools and dies for improved finish.	Improves surface finish, reduces friction, and enhances aesthetic appearance.	Precision molds, dies, and decorative tooling for industries such as automotive and electronics.
Hard Coating	Applying a tough, wear-resistant coating to the die surface to enhance its hardness.	Improves wear resistance, reduces friction, and extends tool life in harsh environments.	Molds, cutting tools, industrial dies, and high-performance tooling in the aerospace, automotive, and medical industries.

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How To Choose the Tool And Die

Choosing the right tool and die involves considering material durability, heat resistance, and wear resistance. Prioritize efficient tool design, including proper cooling, ejection systems, and gate placement for optimal metal flow. Ensure the die meets required tolerances, is easy to maintain, and can handle the production volume. Evaluate cost-effectiveness and long-term maintenance for better manufacturing efficiency.

Choice Factor	Description
Material Selection	Choose tool steel materials like H13, D2, or P20 for durability, heat resistance, and wear resistance.

Tool Design	Ensure the die is designed for efficient metal flow, proper cooling, and ease of part ejection. Consider features like cooling channels and ejector pins.

Mold Surface Finish	Use polished surfaces for better flow and minimal friction. Textured finishes may be used for aesthetic parts.

Ejection System	Choose an efficient ejection system such as ejector pins, lifters, or stripper plates to ensure smooth part release and avoid defects.

Gate and Runner Design	Select proper gate locations and runner systems to control the flow of molten metal, minimize waste, and reduce cold shuts.

Cooling System	Incorporate adequate cooling channels to control the cooling rate and ensure uniform solidification to avoid defects like shrinkage.

Die Maintenance	Choose a tool that is easy to maintain with replaceable inserts or cores for wear protection and ease of repair.

Tolerances	Ensure the die is capable of meeting the required dimensional tolerances, typically in the range of ±0.1mm to ±0.5mm.

Heat Treatment	Use heat treatments like vacuum hardening to improve the die’s hardness and resistance to thermal fatigue, especially for high-temperature applications.

Cost and Production Volume	Consider the cost of tooling relative to the production volume. For high-volume production, invest in more durable, expensive tools, while for lower volumes, more cost-effective tools may be preferred.