FAQ

The advantages and characteristics of high-pressure die casting include:

1. High precision and detail: High-pressure die casting can produce parts with precise dimensions and intricate details, making it suitable for precision components.
   
   

2. High production efficiency: The production speed of high-pressure die casting is fast, making it ideal for mass production and effectively reducing the unit production cost.
   
   

3. High material utilization: Materials like aluminum alloys or zinc alloys are efficiently utilized during the casting process, reducing waste.
   
   

4. Excellent mechanical properties: High-pressure castings typically have good strength and rigidity, making them suitable for a wide range of applications.
   
   

5. Good corrosion resistance: High-pressure die-cast materials, such as alloys, have excellent corrosion resistance, making them suitable for outdoor or humid environments.
   
   

6. Reduced processing time: The complex shapes of the products can be realized during the casting process, reducing the need for subsequent machining.
   
   

These advantages make high-pressure die casting widely used in industries such as automotive, electronics, home appliances, and industrial equipment.

The material properties of zinc alloy and aluminum alloy differ and are suitable for different applications. Here are the main characteristics:

Zinc Alloy Properties

1. Density: The density of zinc alloy is approximately 0.670 g/cm³.
   
   

2. High fluidity: Zinc alloy has better fluidity than aluminum alloy, making it suitable for casting fine and complex shapes.
   
   

3. Excellent surface finish: Zinc alloy has a finer surface compared to aluminum alloy and is easier to treat with processes like electroplating, PVD, etc.
   
   

4. Cost-effective: Zinc alloy is relatively low-cost compared to other metal materials, offering good economic value.
   
   

5. Recyclability: Zinc alloy can be recycled, which minimizes environmental impact.
   
   

Aluminum Alloy Properties

1. Density: The density of aluminum alloy is approximately 0.270 g/cm³.
   
   

2. Lightweight: Aluminum alloy has a lower density than zinc alloy, making it ideal for applications where weight reduction is crucial, such as in aerospace and automotive industries.
   
   

3. High strength and rigidity: Aluminum alloy performs well in strength and rigidity, capable of handling heavy loads.
   
   

4. Good corrosion resistance: Aluminum alloy forms an oxide film, which gives it excellent corrosion resistance.
   
   

5. Good thermal conductivity: Aluminum alloy has excellent thermal conductivity, making it suitable for heat exchangers and thermal management components.
   

6. High machinability: Aluminum alloy is easy to machine, making it suitable for various post-processing operations.

Zinc alloy has excellent fluidity at high temperatures, allowing it to fill complex mold shapes and produce intricate parts. It is easy to perform surface treatments such as electroplating and painting, which can enhance appearance and durability.

Aluminum alloy is suitable for products that require lightweight and high strength. Choosing the right material based on specific needs can improve product performance and cost-effectiveness.

The mold life and shot count of zinc alloy and aluminum alloy differ significantly, mainly due to material properties, mold design, and operating conditions. Here's a comparison:

Zinc Alloy Mold

1. Mold life: Zinc alloy molds generally have a longer lifespan due to their lower melting point (approximately 385°C), which causes less thermal shock and reduces wear. Mold materials typically use wear-resistant steel, and zinc alloy has a lower thermal fatigue effect during cooling, extending mold life.
   
   

2. Shot count: Zinc alloy molds can last between 300,000 to 500,000 shots, depending on the mold design, material, and production environment. Zinc alloy molds maintain stable production efficiency in mass production.
   
   

Aluminum Alloy Mold

1. Mold life: Aluminum alloy has a higher melting point (approximately 660°C), causing more wear and thermal fatigue, resulting in shorter mold life. Higher-performance mold materials (like steel) are required to withstand high temperatures, which increases costs.
   
   

2. Shot count: Aluminum alloy molds typically last between 70,000 to 100,000 shots, depending on design and usage conditions. Due to the high temperature's effects, aluminum alloy molds are more prone to cracking and deformation.
   
   

Choosing the right alloy and mold material, along with proper design and production conditions, can effectively extend mold life and shot count.

LAI YUE provides design suggestions during the quotation phase, such as draft angles, shrinkage, transition radii, and wall thickness.

With over 35 years of experience in casting and mold design, LAI YUE’s integrated design and manufacturing capabilities offer the most professional advice and support.

1. Anodizing
   Characteristics: Forms an oxide layer on aluminum and its alloys, enhancing corrosion and wear resistance.
   Colors: Silver, black, gold, blue, red, etc.
   
   

2. Electroplating
   Characteristics: Uses electric current to deposit metal ions on the substrate, improving appearance and corrosion resistance.
   Colors: Silver, gold, copper, black, depending on the metal used.
   
   

3. Powder Coating
   Characteristics: Uses powder resin coating that is heated and cured to form a uniform layer.
   Colors: A wide range of colors and finishes, such as glossy, matte, metallic, etc.
   
   

4. Spray Painting
   Characteristics: Spray-applied paint that evenly covers the substrate.
   Colors: Various colors, from basic to metallic and gloss finishes.
   
   

5. Electropolishing
   Characteristics: Uses electrochemical methods to remove surface flaws, improving shine.
   Colors: Usually maintains the natural metal color but enhances brightness.
   
   

6. Sandblasting
   Characteristics: Uses abrasive particles to strike the surface, removing oxide layers and dirt, creating a rough finish.
   Colors: Generally does not change the material's color but prepares the surface for further treatment.
   
   

7. Chemical Treatment
   Characteristics: Changes surface properties through chemical reactions, such as rust-proofing or passivation.
   Colors: Depends on the treatment method, typically does not significantly alter color.
   
   

8. PVD (Physical Vapor Deposition)
   Characteristics: Deposits metal vapor onto the substrate in a vacuum, forming a thin film.
   Colors: Gold, black, rainbow, and other effects.
   
   

Different surface treatments and colors can be selected based on specific needs to enhance both product performance and visual appeal.

1. Quality Management System
   ISO Standards: Implementing quality management systems like ISO 9001 to ensure compliance with international standards.
   Continuous Improvement: Using PDCA (Plan-Do-Check-Act) cycles to continuously assess and improve the production process.
   
   

2. Raw Material Control
   Supplier Evaluation: Selecting reliable suppliers and regularly assessing their quality management capabilities.
   Incoming Material Inspection: Checking all incoming materials to ensure they meet specifications.
   
   

3. Production Process Control
   Standard Operating Procedures (SOP): Creating detailed manuals to ensure all employees follow the same procedures.
   Equipment Maintenance: Regularly inspecting and maintaining production equipment to prevent defects caused by equipment failure.
   
   

4. Quality Inspections
   In-process Inspections: Conducting random checks during production to identify and address issues promptly.
   Final Inspection: Performing a final quality check after product completion to ensure it meets specifications.
   
   

5. Statistical Process Control (SPC)
   Data Analysis: Using statistical tools to analyze production data and monitor process variations, taking timely actions when necessary.
   Control Charts: Monitoring the stability and consistency of production processes using control charts.
   
   

6. Customer Feedback
   Collecting Feedback: Actively gathering customer opinions and suggestions to understand the product's actual performance.
   Improvement Measures: Using customer feedback to make improvements and enhance product quality and customer satisfaction.