Low Pressure Die Casting Mould

Low-pressure casting molds offer an indispensable solution for those seeking excellence in the metal casting industry. Injecting metal into the mold with low pressure not only produces high-quality and flawless parts but also minimizes material waste and allows for detailed surface quality on complex geometries.

These molds, which have a wide range of applications in critical sectors such as automotive, aerospace, and defense industries, offer superior performance in the production of high-strength and precision parts. With our low-pressure casting molds, you can achieve cost advantages even in large-scale productions while elevating your quality standards to the highest level.

On our website, you can find comprehensive information about low-pressure casting molds, including details on factors affecting prices and mold design processes. Additionally, comparisons with high-pressure casting molds and solutions to potential problems you may encounter during production are also provided for you.

For those seeking quality and efficiency together, low-pressure casting molds are the right choice. Contact us for more information and to bring your projects to life.

Low-Pressure Casting Molds: High Quality and Detailed Production

Low-pressure casting molds produce high-quality parts by injecting metal into the mold under low pressure. This method reduces material waste and provides detailed surface quality even in complex geometries.

Advantages:

High Quality: Flawless, void-free parts.
Less Material Waste: Only the required amount of metal is used.
Detailed Surface Quality: Thin and complex parts.

Applications:

Automotive: Engine blocks, wheels.
Aerospace: Precision and durable parts.
Defense Industry: High-strength productions.

These molds offer cost and quality advantages in large-scale productions.

Low-Pressure Casting Mold Prices: What Affects Them?

Low-pressure casting mold prices vary depending on several factors. The size, complexity, material type, production volume, and special design requirements of the mold determine these prices.

Factors Affecting Price:

Size and Geometry: Larger and more complex molds are more expensive.
Material Type: High-quality materials increase costs.
Production Volume: Costs may decrease with high volumes.
Special Design: Special requests can raise the price.
Labor and Production Time: These factors also affect the price.

Prices can range from a few thousand dollars to tens of thousands in large projects. Contact us with your project for a precise quote.

Low-Pressure Casting Mold Design: Key Elements

The design of a low-pressure casting mold should be optimized for injecting metal under low pressure. Here are the key elements to consider in this design:

1. Mold Material Selection:

Durability: Steel or alloys that withstand high temperatures and pressures are preferred.
Thermal Conductivity: Good thermal conductivity is required for proper cooling.

2. Mold Geometry:

Balance of Thickness and Thinness: A balanced design is essential to ensure that every part of the component is properly filled.
Complex Shapes: Design must be suitable for detailed geometries.

3. Riser and Gating System Design:

Gating System: Ensures smooth flow of molten metal.
Risers: Prevents voids and defects.

4. Cooling Channels:

Balanced Cooling: Cooling channels are important for quality.

5. Venting Systems:

Gas Vent Channels: Allows gases to escape, preventing defects.

6. Part Removal (Demoulding):

Ejection Mechanisms: Proper mechanisms must be designed to remove the part smoothly.

7. Simulation and Prototyping:

CAD and Simulation: Identifies potential issues in advance.
Prototyping: Tests the accuracy of the design.

Proper design enhances the efficiency of the low-pressure casting process and reduces production costs.

Using a Low-Pressure Casting Mold: Steps and Considerations

A low-pressure casting mold is used for producing high-quality parts with complex shapes and thin wall thicknesses. Here are the basic steps to follow when using these molds:

1. Preparing the Mold:

Cleaning and Inspection: The mold should be cleaned and inspected for damage.
Coating Application: A coating is applied to prevent metal adhesion, which also extends the mold's life.

2. Metal Melting and Casting Preparation:

Metal Melting: The metal is melted to the casting temperature and stirred for a homogeneous structure.
Pressure Settings: Casting pressure is adjusted according to the part and metal type.

3. Casting Process:

Metal Injection: Molten metal is injected into the mold at low pressure, ensuring that the metal fills all cavities.
Cooling Time: The cooling time of the metal should be carefully controlled.

4. Part Removal from the Mold:

Demoulding: The part is carefully removed from the mold after it has cooled.
Ejector Pins: Used to remove the part without damage.

5. Final Processing:

Cleaning: The part is cleaned of any residues.
Cutting and Grinding: Gates and risers are removed.
Quality Control: The parts are inspected according to quality standards.

6. Mold Maintenance:

Mold Maintenance: The mold is preserved with regular maintenance and coating processes.

7. Mold Storage:

Storage: Stored under suitable conditions after use, extending the mold's life.

Proper mold usage optimizes the production process, enhances part quality, and reduces costs.

Low-Pressure Casting Mold vs. High-Pressure Casting Mold: Comparison

Low-pressure casting molds and high-pressure casting molds are two different methods used in metal casting. Each offers advantages depending on specific production needs. Here are the main differences between these two methods:

1. Pressure Level:

Low-Pressure Casting: Metal is injected into the mold at a low pressure of 1-5 bar.
High-Pressure Casting: Metal is injected at high pressure, ranging from 100-150 bar.

2. Mold and Part Quality:

Low-Pressure Casting: Produces high-quality parts with low internal stress. Suitable for complex geometries.
High-Pressure Casting: Faster production but with higher risks of internal stress and voids.

3. Application Areas:

Low-Pressure Casting: Used in automotive, aerospace, and defense industries.
High-Pressure Casting: Ideal for mass production, such as electronic housings.

4. Production Speed:

Low-Pressure Casting: Slower, suitable for small-volume production.
High-Pressure Casting: Fast production, ideal for large-volume productions.

5. Cost:

Low-Pressure Casting: Higher mold cost, but offers quality advantages.
High-Pressure Casting: Lower mold cost, cost-effective in high-volume production.

6. Mold Life:

Low-Pressure Casting: The mold life is longer due to low pressure.
High-Pressure Casting: The mold wears out faster due to high pressure.

7. Post-Processing Requirements:

Low-Pressure Casting: Requires less post-processing.
High-Pressure Casting: May require more post-processing.

8. Gas Trapping:

Low-Pressure Casting: Lower risk of gas trapping.
High-Pressure Casting: Higher risk of gas trapping due to high pressure.

This comparison helps you understand the advantages and disadvantages of low-pressure and high-pressure casting methods. The choice depends on your production needs and part specifications.

Low-Pressure Casting Mold Manufacturing: Steps and Considerations

Low-pressure casting mold manufacturing is a critical process for producing precise and high-quality casting parts. Here are the key steps of this process:

1. Design Phase:

Part Design: The dimensions and geometry of the part to be cast are determined.
Mold Design: A 3D model is created and optimized through casting simulations.
Simulation: Potential errors are identified and the design is improved.

2. Material Selection:

Mold Material: Steel alloys resistant to high temperatures and pressures are preferred.
Coating Material: A coating is applied to prevent the adhesion of molten metal.

3. Mold Manufacturing:

CNC Machining: The mold's internal cavity, gating system, and cooling channels are created.
Cooling Channels: Placed for proper cooling and to reduce internal stresses.
Assembly: The mold parts are assembled and prepared for final use.

4. Mold Testing and Prototype Production:

Test Casting: The mold is tested before going into production.
Prototype Production: The produced parts are examined and the mold is adjusted if necessary.

5. Quality Control and Approval:

Quality Control: Dimensional accuracy and surface quality are checked.
Approval and Mass Production: The mold is approved and prepared for mass production.

6. Mold Maintenance and Service:

Regular Maintenance: The mold is regularly cleaned and maintained.
Repair and Revision: Any damage during use is repaired.

This process ensures that the mold is long-lasting and that the produced parts meet the desired quality standards.

Advantages of Low-Pressure Casting Mold

The use of low-pressure casting molds offers numerous advantages in the production of high-quality and precise casting parts. Here are the main advantages of this method:

1. High Part Quality:

Low Porosity: Provides more dense and durable products with minimal porosity in parts.
Flawless Surface: High surface quality reduces the need for post-processing.

2. Detailed and Complex Geometries:

Complex Shapes: Parts with thin walls and complex geometries can be produced.
Thin Wall Thicknesses: Light and durable products are obtained.

3. Reduced Internal Stress and Cracking Risk:

Balanced Cooling: Reduces internal stress and cracking risk.
Long-Lasting Parts: Produces long-lasting parts that require less maintenance.

4. High Production Efficiency:

Fewer Defects: Reduces casting defects and scrap rate, increasing efficiency.
Reduced Post-Processing: Less post-processing requirement reduces costs.

5. Wide Range of Material Options:

Different Alloys: Various alloys like aluminum, magnesium, and copper can be used.
High-Strength Materials: Advantageous in industries such as automotive and aerospace.

6. Cost-Effectiveness:

Low Production Cost: Offers a cost-effective solution in mass production.
Long Mold Life: Low-pressure casting extends the life of molds.

7. Flexible Production Capacity:

Different Sizes and Shapes: Various part sizes and shapes can be produced.
Fast Prototyping: Design changes can be quickly implemented.

These advantages make the low-pressure casting method an ideal choice, especially in industries that require high-quality, precise, and complex part production.

Production Process with Low-Pressure Casting Mold

Production with a low-pressure casting mold enables the production of high-quality and precise metal parts. The process involves injecting metal into the mold under low pressure and consists of the following main stages:

1. Preparation Phase:

Mold Design and Manufacturing: The part and mold design are done with 3D models. The mold is manufactured with CNC machines, and cavities, runners, and cooling channels are carefully machined.
Material Preparation: The metal is melted to the casting temperature, and a coating is applied to prevent adhesion to the mold.

2. Casting Process:

Metal Injection: The metal is injected into the mold at a pressure of 1-5 bar, filling all cavities.
Cooling and Solidification: The metal cools evenly within the mold, and gases are vented through the channels.

3. Part Removal from the Mold:

Mold Separation: After cooling, the part is removed from the mold using ejector pins or cores.
Cleaning and Final Processing: Runners and risers are removed, and the surface is cleaned.

4. Quality Control and Tests:

Visual and Dimensional Inspections: The surface and dimensions of the part are inspected.
Mechanical Tests: Strength and internal structure tests are conducted.

5. Final Product Approval and Storage:

Product Approval: Parts that pass all tests are approved.
Storage and Shipment: Approved products are stored and prepared for shipment.

6. Mold Maintenance and Service:

Regular Maintenance: The mold is cleaned and repaired after each casting.
Mold Storage: Stored under appropriate conditions when not in use.

This process ensures the production of high-quality, durable, and precise parts with low-pressure casting. Each step should be carefully applied to increase production quality and efficiency.

Low-Pressure Casting Mold Materials

The materials used in the production of low-pressure casting molds directly affect the durability of the mold and the quality of the produced parts. These materials must resist high temperatures, pressure, and wear. Here are the common materials used in low-pressure casting molds:

1. Mold Steels:

H13 Steel: Known for its high-temperature resistance and wear resistance.
P20 Steel: Suitable for complex geometries with moderate wear resistance.
D2 Steel: Provides high hardness and wear resistance, extending the mold's life.

2. Alloy Steels:

Maraging Steels: Offers excellent toughness and durability.
Chromium-Molybdenum Steels (CrMo): Resistant to high temperatures, with thermal resistance.

3. Nickel Alloys:

Inconel: Provides excellent corrosion resistance at high temperatures.
Nickel-Chromium Alloys: Known for thermal fatigue resistance, suitable for aluminum and magnesium castings.

4. Graphite Materials:

Isostatic Graphite: Enhances surface quality with high-temperature resistance and thermal conductivity.
Electrographite: Reduces metal adhesion, facilitating easy mold release.

5. Copper Alloys:

Beryllium Copper: Offers high thermal conductivity, used in gating and riser systems.
Bronze: Provides good wear resistance and thermal conductivity.

6. Ceramic Materials:

Zirconia Ceramics: Resistant to erosion and corrosion, with high-temperature resistance.
Alumina Ceramics: Provides high hardness and wear resistance.

7. Coating Materials:

Titanium Nitride (TiN): Increases wear resistance and extends mold life.
Chromium Coating: Increases surface hardness and provides corrosion resistance.

8. Materials for Cooling Channels:

Copper Tubes: Offers high thermal conductivity.
Stainless Steel Tubes: Highly resistant to corrosion, ensuring long service life.

These materials enhance the efficiency and durability of low-pressure casting molds, ensuring the quality of the produced parts.

Low-Pressure Casting Mold Problems and Solutions

Problems encountered in low-pressure casting molds can reduce production efficiency and affect part quality. Here are common problems and their solutions:

1. Porosity:

Problem: Caused by improper metal flow or trapped gases.
Solution: Vacuum application, low-pressure usage, and cooling control reduce porosity.

2. Cooling Cracks:

Problem: Caused by rapid cooling, leading to internal stresses and cracks.
Solution: Improve mold design, extend cooling time, and use coatings to prevent cracks.

3. Casting Defects and Errors:

Problem: Caused by the metal not fully filling the mold cavities.
Solution: Increase filling pressure, preheat the mold, and optimize the gating system to reduce errors.

4. Gas Trapping:

Problem: Gases trapped inside the mold.
Solution: Gas vent channels, low-pressure usage, and a vacuum system prevent gas trapping.

5. Surface Defects:

Problem: Surface roughness and cracks.
Solution: Polishing the mold surface, applying coatings, and balanced cooling reduce surface defects.

6. Mold Wear:

Problem: Mold wear due to continuous use.
Solution: Using high-durability materials, regular maintenance, and coating technologies reduce wear.

7. Insufficient Mold Filling:

Problem: The metal not fully filling the mold cavities.
Solution: Increase casting temperature, optimize mold temperature, and improve the gating system to enhance filling.

These solutions minimize problems in the low-pressure casting process, ensuring the production of higher-quality parts. These strategies can be applied to optimize the production process.