In-Depth Analysis of Core Processes in Aluminum Alloy Die Casting: Molds Design and Molding Technologies

In-Depth Analysis of Core Processes in Aluminum Alloy Die Casting: Molds Design and Molding Technologies

As a crucial process for efficiently manufacturing lightweight components, aluminum alloy die casting relies on mold design and molding technologies as the core determinants of product quality and production efficiency.

In terms of mold design, structural rationality is of utmost importance. The design of the gating system requires precise control over the flow path and velocity of aluminum liquid. Through the optimized combination of a runner cone, horizontal runners, and ingates, the aluminum liquid can be filled into the cavity rapidly and smoothly, reducing eddies and gas entrapment. For example, using fan-shaped ingates can evenly disperse the aluminum liquid, avoiding local overheating and cold shut defects. The design of the mold cooling system directly impacts both production efficiency and casting quality. Reasonable arrangement of cooling channels ensures uniform mold temperature, accelerating the solidification of castings, shortening the molding cycle, and preventing casting deformation caused by excessive temperature differences. Additionally, the selection of mold materials cannot be overlooked. Hot work die steels such as H13, with their excellent thermal fatigue resistance, wear resistance, and toughness, are commonly used materials for aluminum alloy die-casting molds.

Regarding molding technologies, parameter control during the die-casting process is key. The injection pressure of the die-casting machine needs to be adjusted according to the aluminum alloy grade and casting structure. Higher injection pressure can enhance the density of castings, but excessive pressure will accelerate mold wear. The injection speed affects the filling effect of the aluminum liquid; rapid injection can reduce oxidation inclusions and prevent the formation of air holes. Meanwhile, mold preheating and spraying processes also require strict control. An appropriate mold temperature can improve the fluidity of the aluminum liquid, and applying release agents not only facilitates demolding but also assists in mold heat dissipation. Only by precisely controlling all aspects of mold design and molding technologies can high-quality and high-efficiency production of aluminum alloy die castings be achieved.