Precision Die Cast
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Precision Die Cast

Precision die casting is an advanced form of traditional die casting. It achieves near-net-shape forming through controlled atmosphere and precise process control, making it ideal for precision parts with stringent requirements for dimensional stability and mechanical properties.

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Product Introduction

Precision Die Casting

Core Definition

Core Implementation Path

Material Melting: High-purity alloy refining, with aluminum hydrogen content ≤0.1 ml/100 g Al; furnace feeding temperature fluctuations controlled within ±5 °C.

Injection Vacuum: Closed-loop injection system with curve fluctuation <2%; cavity vacuum maintained at 50–90 mbar; secondary extrusion is possible in thick-walled areas (>1000 bar).

Intelligent Control: Multi-zone mold temperature control (±3 °C), with full parameter monitoring to achieve statistical process control (SPC).

Core Advantages and Limitations

Advantages:

Mechanical performance comparable to forgings.

Near-net-shape forming of complex parts, cost-effective for medium to large batches.

High design freedom, heat-treatable, excellent airtightness.

Dense internal structure and high reliability.

Limitations:

High equipment and mold investment.

Requires specialized technical expertise.

Demands careful design to achieve optimal results.

Main Applications

Automotive: Shock absorber towers, motor housings, etc.

New Energy Vehicles: Battery pack housings and electric drive system components.

High-End Communication Electronics: 5G base station antenna housings, etc.

Medical Instruments: Equipment brackets, precision housings, etc.

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Frequently Asked Questions

Q1: Are parts requiring T6 heat treatment suitable for precision die casting?

A: Yes. Traditional die casting can blister during heat treatment due to porosity, whereas precision die casting ensures high internal density and meets heat treatment requirements.

Q2: Can precision die casting completely eliminate porosity? What are the standards?

A: Precision die casting achieves near-zero porosity, with an overall porosity rate ≤1% and critical areas ≤0.5%, conforming to ASTM E505 Level 1 or higher. Helium leak testing is possible for all parts.

Q3: How do I choose between precision die casting and traditional die casting plus machining based on cost?

A: For complex parts with large machining areas, precision die casting is generally more cost-effective. For simple parts, traditional die casting plus machining may be cheaper.

Q4: Why is the development cycle for precision die casting longer?

A: It requires additional detailed CAE simulations, vacuum system testing, and process window calibration to ensure successful mass production.

Q5: Can all die casting factories perform precision die casting?

A: No. Precision die casting requires specialized hardware, software knowledge, and a multidisciplinary engineering team. When selecting a supplier, reviewing successful case studies is crucial.

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