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Dongguan Chengzhu Metal Products Co., Ltd. was established on April 28, 2013. It is an enterprise integrating the molding, research and development, production and marketing of light alloy materials.

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The business scope includes the manufacturing of precision die casting molds for magnesium alloys, aluminum alloys and other light alloys, and the R&D, design, production and sales of die castings.

Widely Used Products

Products are mainly used in medical equipment, unmanned aircraft parts, robot/manipulator parts, new energy vehicle parts, motorcycles, electric vehicles, Motorized scooter, electric tools, sports equipment, 3C, LED, industrial parts and other fields.

What Are the Products of Electric Scooters And Bikes

Handle Aluminum And Magnesium Alloy Die Castings

Aluminum Magnesium Alloy Die-Casting Parts

Front Fork Die-Casting Magnesium Alloy Castings

Folder Aluminum Alloy Accessories

Aluminum Magnesium Alloy Casting

Front Fork Die-Casting Castings

Rear Wheel Bracket Magnesium Alloy Casting

Handle Aluminum Alloy And Magnesium Alloy Castings

Electric Vehicle Motor Hub Casting

What Is Aluminum Magnesium Alloy Die-Casting Part

Aluminum magnesium alloy die-casting part is a specialized manufacturing process utilized in the production of metal parts and components made from magnesium alloy. This process, often referred to as magnesium alloy die casting, involves injecting molten magnesium into a die or mold cavity under high pressure. The resulting product, also known as magnesium cast, is a complex shape or part that exhibits the unique properties of magnesium alloy.

The die casting manufacturing process for magnesium starts with the preparation of the magnesium alloy. The alloy is carefully melted in a furnace and subsequently injected into the die or mold cavity. Typically, the mold is constructed from durable materials such as steel and is meticulously designed to produce the desired shape of the final part.

Once the molten magnesium is introduced into the mold cavity, it undergoes rapid cooling and solidification under high pressure. This distinctive manufacturing method allows for the creation of intricate and complex shapes that would be challenging to achieve through alternative manufacturing processes.

Handle Aluminum And Magnesium Alloy Die Castings

Process of Aluminum & Magnesium Die Casting

Both aluminum and magnesium are typically cast using the high-pressure die casting process. The process consists of the following steps:
Melt the Metal: Start by melting the metal to be cast.

Handling Molten Metal:
1. For aluminum, use a ladle to transfer the molten aluminum manually.
2. For magnesium, keep the molten magnesium alloys in a sealed furnace inside the equipment.

Injection: Use a plunger to push the molten metal into the die cavity.

Solidification: Allow the molten metal to solidify.

Ejection: Finally, eject the solidified casting.

Magnesium Alloy Parts Die-Casting Type

There are two main types of die casting: hot chamber and cold chamber. Magnesium alloys can be die cast using either process. The two methods are described in more detail below:

Hot Chamber Die Casting

Hot chamber die casting, also known as "gooseneck" or "hot" casting, is the more commonly used die casting method. In hot chamber die casting, one end of a gooseneck-shaped pathway is submerged in a closed bath of molten metal. To prevent freezing of the metal, the nozzle is heated to 400–500 °C with gas, electric, or by induction heating. When the die-casting process starts, a hydraulic piston forces the molten metal from the bath, through the gooseneck feed system, and into the cavity. Hot chamber die casting is primarily used with metals having low melting points such as zinc, tin, or lead (whose melting points are between 450°F and 787°F). However, magnesium, which has a melting point of around 1100°F, can also be used for hot chamber die casting.
Hot chamber die casting limits the molten material's exposure to ambient air which helps to prevent oxide inclusions in the casting. This is because a cover gas, typically sulfur hexafluoride, is dispersed and protects the molten material.
Hot chamber magnesium die casting is great for producing large volumes of parts. This is because cycle times in hot chamber magnesium die casting are shorter compared to cold chamber die casting since the furnace and casting portion of the machine is integrated together. This prevents the need to transport molten material and superheat the material — two processes that are required in cold chamber casting and take additional time.

However, hot chamber die casting produces parts that are more porous than cold chamber die casted parts since entrapped gases from the injection process are more likely to occur due to the high injection velocity.

Additionally, hot chamber die casting is more expensive than cold chamber die casting since die casting machinery equipment is more likely to corrode due to continuous exposure to heightened temperatures. Consequently, maintenance is more costly in the long run.

Cold Chamber Die Casting

Cold chamber die casting, also known as cold casting, is the die-casting process that involves melting metal in a separate furnace and pouring the molten metal into an unheated chamber for injection into the mold under high pressure. It is best for metals with higher melting temperatures, like magnesium, aluminum, and copper. Like in hot chamber die casting, a cover gas is used to protect the molten magnesium and prevent oxides from forming in the casted part. Cold chamber die casting is the more cost-effective type of die casting since it requires less maintenance. However, cycle times with cold chamber die casting are longer, and product quality may be lower than that of hot chamber die casting. This is because the high pressure used in cold chamber casting can lead to an inability to vacate gases before the solidification process.
While magnesium alloys are suitable for both hot and cold chamber die casting due to the presence of alloying elements that can reduce the particular alloy's melting temperature, cold casting is more commonly used in magnesium die casting due to the material's high melting point. Die-casting machinery capable of melting metal in the same machine as the molding system, as is done in hot chamber die casting, is expensive. Many manufacturers opt to use the cold chamber process, in which the magnesium is melted in a separate furnace and transferred into the die-casting machine for molding.

Reasons for Choosing Magnesium for the Die-Casting

Magnesium is 75% lighter when compared to steel. It offers no particular loss of strength. The castings of magnesium can meet high tolerances that aren't possible with steel. It is considered a compatible material for complex, thin-walled, net-shape, and near-net-shape castings. Moreover, it gives strong dimensional stability, and hence it is preferred. Even, the tooling costs are lower for magnesium castings. It allows to assemble multiple components as a single unit, hence, reducing welding and assembly costs. Also, it offers component rigidity, thus, providing its retention capacity for a long time. For aluminum, magnesium is 33% lighter. As a result, one can see the improvised mechanical properties of the component.

Additionally, the machines function better with it and so the process becomes easier. It is also more resistant to corrosion and shows appreciable performance in large, thin-wall, net-shape complex parts. Compared to plastic, magnesium offers greater strength. It is much stiffer than advanced engineering plastics. It not only offers energy resistance features but also wear resistance and higher temperature resistance. Therefore, magnesium die-casting shows quite developed properties in comparison to steel, aluminum, and plastic. These are the reasons industrialists choose magnesium for die casting.

Aluminum Magnesium Alloy Die-Casting Part Design Guidelines

Die casting draft angles
One of the most critical design features in die casting is adding a draft or draft angle. The draft is the taper applied to the surfaces on the part perpendicular to the parting line and, consequently, on the die cavity. It is vital to include the correct amount of draft. Otherwise, parts can get stuck in the die, causing damage to the part and, worse, the die. It is best practice to consider drafts early in the design process to avoid significant redesign later.
Drafts start on the parting line, and for most geometric features in aluminum magnesium alloy die-casting part, a common draft angle of 2.0 degrees can be applied. The amount of draft will have different calculations depending on whether they are on an inside wall, outside wall or hole.

Smooth sharp corners
Sharp corners and edges can be problematic as they create areas of high stress on the part and mould. Therefore, adding the largest feasible fillet to your design is advised to increase the structural integrity of the part and tool life. The metal can flow freely in the mould by smoothly transitioning between surfaces.
● Advised corner radius: 1 mm
● Minimum corner radius: 0.5 mm

Undercuts
Undercuts are overhanging features that can not be machined with a straight-cutting tool. Try to avoid undercuts and overhangs in your design. However, if these are required, add additional design features, such as slots, to reduce the tooling complexity. If it is impossible to redesign your part to eliminate undercuts sliding cores can be added. Cores are inserts that can slide in and out of the mould to create features such as undercuts. These add complexity and cost to a mould and should be avoided.

Uniform wall thicknesses
The wall thickness throughout the aluminum magnesium alloy part should be uniform or as consistent as possible. This reduces the chance of distortion when the part cools and shrinks. Furthermore, a constant wall thickness helps to ensure that the die fills evenly. An inconsistent wall thickness can result in cold shuts - a defect whereby the molten aluminum magnesium alloy cools and solidifies before filling the mould.

Shrinkage
When the molten metal slows down and cools in the die, the material shrinks. Material shrinkage is unavoidable, so it must be considered when designing the tooling. Thicker sections are more susceptible to shrinkage and, thus internal pores. To reduce shrinkage, it is recommended to:
● Avoid large thick sections in your design
● Adding ribs to walls can reduce shrinkage effects
● Squeeze pins can be added to features to reduce the shrinkage porosity

Parting lines
The parting line or plane is where the two die halves split. It is important to determine the location and type of parting line early when designing your parts to avoid any issues arising with undercuts or draft angles. This line's placement mainly depends upon the type of geometrical shape of the part.

Our Factory

Dongguan Chengzhu Metal Products Co., Ltd. was established on April 28, 2013. Its registered address is located at No. 1, 1st Street, Fujie, Tangqiu Village, Liaobu, Dongguan City. Its legal representative is Zhao Chenhuang, with a registered capital of 3 million yuan. It is an enterprise integrating the molding, research and development, production and marketing of light alloy materials, and a well-known enterprise in Guangdong Province producing light alloy products.
The business scope includes the manufacturing of precision die casting molds for magnesium alloys, aluminum alloys and other light alloys, and the R&D, design, production and sales of die castings, which are mainly used in medical equipment, unmanned aircraft parts, robot/manipulator parts, new energy vehicle parts, motorcycles, electric vehicles, Motorized scooter, electric tools, sports equipment, 3C, LED, industrial parts and other fields.

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FAQ

Q: What is aluminum magnesium alloy die-casting part?

A: A manufacturing process that produces accurately, defined, smooth and textured-surfaced metal parts. Accomplished by forcing molten metals into a mold form due to high-pressure systems. Corrosion resistant. Highly conductive. Have a good stiffness and strength-to-weight ratio.

Q: What are the advantages of aluminum magnesium alloy die-casting part?

A: Magnesium is a common element added to a wide range of alloys because it can add strength without inhibiting the positive characteristics of the base metal. With magnesium in aluminum, the aluminum has added strength, corrosion resistance and good weldability characteristics.

Q: What is aluminum magnesium alloy die-casting part used for?

A: The range of applications is immense when using aluminum alloys that have magnesium added. Aluminum with magnesium can be formed into train bodies, truck bodies, armored vehicles, building construction, pressure vessels, chemical tankers, ships, and lids on aluminum beverage cans.

Q: What is the best aluminum magnesium alloy die-casting part?

A: Alloy A380 has better than average machining characteristics. Alloy 218, with magnesium the major alloying element, exhibits among the best machinability. Alloy 390, with the highest silicon content and free silicon constituent, exhibits the lowest.

Q: What is the difference between cast alloy and alloy?

A: The fundamental difference between cast and wrought alloy is easy to understand: cast alloy is the alloy that was melted in a furnace and poured into a mold and allowed to cool. Wrought alloy is when the alloy is worked in the solid form (stamping, bending, rolling, extrusion, etc.)

Q: What are the 3 basic methods of aluminum magnesium alloy die-casting parts?

A: Three primary metal casting methods can be used to cast aluminum: die casting, permanent mold casting, and sand casting.

Q: What is the raw material for aluminum magnesium alloy die-casting part?

A: The raw material for aluminum magnesium alloy die-casting parts is largely recycled aluminum cans and other articles. The first step in an aluminum magnesium alloy die-casting part operation is to crush, shred, and sort the raw material.

Q: How strong is aluminum magnesium alloy die-casting part?

A: Al-Mg alloys possess moderate strength, high corrosion resistance, and appropriate weldability, which can be strengthened by work hardening and solid-solution strengthening.

Q: What is the process of die casting aluminum alloy?

A: Aluminum alloys for die casting are melted in a furnace and then injected into the dies by the die casting machine. Once the liquid aluminum is injected into the dies, it rapidly cools and solidifies into the final cast part.

Q: Why is aluminum magnesium alloy good for die casting?

A: Aluminum magnesium alloys are an excellent choice for die casting as they create lightweight parts with a wide range of finishing options. The alloys have excellent corrosion resistance and can make thin-walled parts due to the alloy's high dimensional stability.

Q: How to design the draft angle of aluminum magnesium alloy die-casting parts?

A: One of the most critical design features in die casting is adding a draft or draft angle. The draft is the taper applied to the surfaces on the part perpendicular to the parting line and, consequently, on the die cavity. It is vital to include the correct amount of draft. Otherwise, parts can get stuck in the die, causing damage to the part and, worse, the die. It is best practice to consider drafts early in the design process to avoid significant redesign later.
Drafts start on the parting line, and for most geometric features in aluminum magnesium alloy die-casting part, a common draft angle of 2.0 degrees can be applied. The amount of draft will have different calculations depending on whether they are on an inside wall, outside wall or hole.

Q: Is the wall thickness of aluminum magnesium alloy die-casting parts uniform?

A: The wall thickness throughout the aluminum magnesium alloy part should be uniform or as consistent as possible. This reduces the chance of distortion when the part cools and shrinks. Furthermore, a constant wall thickness helps to ensure that the die fills evenly. An inconsistent wall thickness can result in cold shuts - a defect whereby the molten aluminum magnesium alloy cools and solidifies before filling the mould.

Q: How to cast aluminum parts?

A: Most aluminum casting processes involve heating the aluminum (and other metal) and pouring them in molten form into a prepared mold with the desired product design. Afterward, the molten aluminum cools down, solidifies, and takes the shape of the cavity.

Q: What is the process of magnesium alloy casting?

A: In the hot chamber die casting method, the molten metal is held in an enclosed steel crucible, under a protective atmosphere. A valve allows a controlled volume of molten metal into the gooseneck that is immersed in the molten metal. A plunger injects this metal into the cavity of the die through a nozzle.

Q: What is die casting alloy?

A: Die casting is a metal casting process that involves feeding molten nonferrous alloys into dies under high pressure and at high speed to rapidly create molded products. The main materials used in die casting are alloys of aluminum, magnesium and zinc.

Q: Is magnesium alloy same as aluminum?

A: While magnesium is lighter, has a lower melting point, and better thermal conductivity, aluminum is stronger and more ductile. When choosing a material for die casting, it is vital to take into account the particular needs of the application and carefully evaluate the advantages and disadvantages of each metal option.

Q: Why is aluminum magnesium alloy good for casting?

A: There are many benefits to casting with magnesium. Not only is magnesium the lightest of all the structured materials but it has excellent stiffness and strength-to-weight ratios. Additionally, it has outstanding EMI and RFI shielding properties, perfect for connectors and electrical housings.

Q: Does aluminum magnesium alloy die-casting part rust?

A: Aluminum magnesium alloy die-casting part is commonly alloyed together with aluminium to provide additional corrosion resistance, but it remains susceptible to corrosion in carbon dioxide or sodium chloride containing environments.

Q: What are the components of aluminum magnesium alloy die-casting part?

A: The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.

Q: What are the two types of aluminum magnesium alloy die-casting?

A: The two main types of die casting processes are hot-chamber and cold-chamber die casting. Variations on these two types of die casting include: Low-pressure die casting. Vacuum die casting.

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