End Cover Aluminum Die Casting Parts

Motor end cover cnc precision machining aluminum die casting​

Aluminum die casting 

The aluminum die-casting parts of the motor end cover we provide are made of aluminum alloy/zinc alloy, and the surface treatment is sandblasting, spraying and polishing to ensure the smoothness and aesthetics of the product. It is used in various industries, aerospace and industries. , Marine Corps, medical, construction, automotive industry, optical, electronic products

Die casting

Die casting is a metal casting process characterized by forcing molten metal under high pressure into the cavity. The mold cavity is made using two hardened tool steel molds that have been processed into a certain shape and work in a similar way to injection molds.

Most die castings are made of non-ferrous metals, especially zinc, copper, aluminum, magnesium, lead, tin and tin-based alloys. Depending on the type of metal being cast, hot or cold chamber machines are used.

Casting equipment and metal molds represent significant capital costs, and this tends to limit the process to mass production. The manufacture of parts using die casting is relatively simple, involving only four main steps, thereby keeping the incremental cost of each product low. It is particularly suitable for a large number of small and medium-sized castings. Therefore, die casting can produce more castings than any other casting process. [1] Die castings are characterized by good surface finish (according to casting standards) and size consistency.

There are two variants of non-porous die casting, which are used to eliminate pore defects. And direct injection die casting, together with zinc castings can reduce waste and increase output.

Hot chamber die casting

Hot chamber die casting, also known as gooseneck machine, relies on a pile of molten metal to feed the mold. At the beginning of the cycle, the piston of the machine retracts, which allows molten metal to fill the "gooseneck". A pneumatic or hydraulic piston then presses this metal from the gooseneck into the mold. The advantages of this system include fast cycle time (approximately 15 cycles per minute) and the convenience of melting metal in the casting machine. The disadvantage of this system is that it is limited to the use of low-melting metals, and aluminum cannot be used because aluminum will absorb some iron in the molten pool. Therefore, hot cell machines are mainly used for zinc, tin and lead-based alloys.

Cold chamber die casting

These materials can be used when casting alloys cannot be used in hot cell machines. These include aluminum, zinc alloys and large amounts of aluminum, magnesium and copper. The process of these machines begins with melting metal in a separate furnace. Then, the precise amount of molten metal is transported to the cold chamber machine, where it is fed into the unheated injection chamber (or injection cylinder). Then, this injection is driven into the mold by hydraulic or mechanical pistons. The biggest disadvantage of this system is the slower cycle time because of the need to transfer the molten metal from the furnace to the cold room machine.

The Best Aluminum Alloys for Die Casting

It is generally agreed that die casting with aluminum is one of the most cost-effective and sustainable ways to create metal parts. When using aluminum, you will have to choose which aluminum casting alloys to use in the process. Here is some technical information on aluminum alloys to help you get a better sense of your alloy options and why we choose the alloys we prefer.

A380 Aluminum Alloy

The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures and corrosion resistant. A380 is also very good at retaining dimensional stability even with complex shapes and thin walls and offers high electrical and thermal conductivity.

A383 Aluminum Alloy

Another option for die casters is to use A383 aluminum alloy. This is alloy is typically only used when you are forming intricate components and require very specific die-filling characteristics. While it doesn’t share all the properties of A380, it does offer higher strength at high temperatures with less chance of cracking under heat.

A360 Aluminum Alloy

A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.

A360 vs. A380 v. A383

To summarize the differences between the three types of casting alloys as outlined above, A360 has the best pressure tightness, high-temperature strength and corrosion resistance of the three alloys.

A380 is also highly corrosion-resistant but more cost-effective and easier to work with than A360, so this is the one you would use most commonly if you have budgetary concerns to consider and don’t need the highest levels of corrosion resistance or pressure tightness.

A383 is a modified A380 alloy you would only use if you need precise die filling that you are not getting from your A380 alloy, as it is not as durable as A380.

ZA Alloys

Some applications may call for ZA, or zinc aluminum alloys, for your die casting. Originally the primary type of alloy used in gravity casting, scientists have refined this type of alloy for effective use in die casting. The three alloys that fall into this category are ZA-8, ZA-12 and ZA-27. Alloys that combine zinc and aluminum offer higher strength, lower density, better creep resistance and better wear resistance than other zinc alloys.

ZA-8

ZA-8 is the only hot chamber alloy of the three. It is the zinc aluminum alloy one uses in die casting with the lowest possible aluminum content. It features an aluminum content of 8.4 percent with one percent copper. Because of the minimal aluminum content, ZA-8 has a lower melting point and higher density than other zinc aluminum alloys. This makes it ideal for hot-chamber die casting. It’s often used for higher strength requirements that need plating.

ZA-12

ZA-12 has somewhat greater aluminum content than ZA-8 but less than ZA-27, so it offers a sometimes desirable mediation of zinc alloy properties. It has 11 percent aluminum and one percent copper content. It provides the best combination of castability and strength of the ZA alloys. Because of its higher melting point and lower density, if you are using ZA-12 for casting, you must use the cold-chamber method.

ZA-27

ZA-27 is the strongest of the three ZA alloys, but difficult to cast. It has the highest aluminum content of all the zinc-aluminum alloys we use for die casting, with an aluminum content of 27 percent and copper content of 2.2 percent. The result is a material with the highest melting point, highest strength and lowest density.

Unlike other zinc aluminum alloy parts, parts made with ZA-27 are typically not ideal for chrome plating. As with ZA-12, you cannot use this alloy with hot-chamber casting because of its high melting point. Underside shrinkage can be an issue in die casting for ZA-27 – so cooling rates need to be looked at carefully.

Aluminum Alloys We Offers

If your component is highly intricate, 383 is often used as an alternative to A380.

It has better corrosion resistances, is lightweight, and its benefits include ease of casting, good mechanical properties, and dimensional stability.

MECHANICAL PROPERTIES

Imperial US/UK | Metric

PHYSICAL PROPERTIES

Imperial US/UK | Metric

COMPOSITION