In modern manufacturing, hardware die castings, with the characteristics of high precision and high efficiency, have become the core choice in fields such as automotive parts, electronic accessories, and industrial equipment. As a metal products factory with more than twenty years of existence, we specialize in the mass production of conventional aluminum alloy and zinc alloy die castings. Through mature processes and strict quality control, we provide customers with customized services that have controllable costs and reliable quality. The following is a full-process analysis from material selection, production process to application cases, which will help you quickly understand the industry value and cooperation advantages of hardware die castings.
I. Material Selection: The Key to Balancing Performance and Cost
1.Aluminum Alloy Die Castings
· Core Advantages: The density is 2.7g/cm³ (only one-third of that of steel), the tensile strength reaches 200-300MPa, and the thermal conductivity is three times that of iron, with both lightweight and heat dissipation performance.
· Typical Applications: Motor end covers of new energy vehicles (weight reduced by 30%), heat sinks of 5G base stations (heat dissipation efficiency increased by 25%), and casings of household appliances (surface treatment qualification rate > 98%).
· Cost Advantage: Using common grades such as ADC12/A380, the raw material cost is 40% lower than that of magnesium alloy, making it suitable for mass production.
2.Zinc Alloy Die Castings
· Technical Highlights: The melting point is 380℃ (only half of that of aluminum), with excellent fluidity, supporting the molding of thin-walled parts with a thickness of 0.5mm, and the surface roughness Ra ≤ 3.2μm.
· Application Scenarios: Precision components of smart locks (lock core matching accuracy ±0.03mm), bathroom hardware accessories (electroplating adhesion reaching grade 5B), and connectors for consumer electronics (plug-in life > 5000 times).
· Processing Efficiency: The mold life can reach 50,000 times, and the production cycle is 20% shorter than that of aluminum alloy.
3.Other Materials
· Copper Alloy Die Castings: Used for bathroom faucets (lead content ≤ 0.8%) and valve accessories (bearing capacity > 10MPa).
· Iron-based Die Castings: Suitable for high-load industrial parts (hardness HRC40-45), such as the housing of agricultural machinery gearboxes.
II. Production Process: Standardized Processes Ensure Stability
1.Mold Design and Manufacturing
· Technical Capabilities: Adopting CAD/CAE collaborative design, simulating the flow of molten metal through Moldflow, reducing the number of trial moldings to 2-3 times; selecting H13 mold steel, with a life of ≥ 30,000 moldings.
· Processing Equipment: CNC machining centers (accuracy ±0.01mm), electrical discharge machining machines (surface roughness Ra ≤ 0.8μm).
· Customized Services: Support mold development (the cost of a single set of molds is 30% lower than that of large enterprises), and the sample-making cycle is 7-15 days.
· Equipment Configuration: A matrix of die casting machines with a capacity of 600-2000 tons, supporting the production of micro parts weighing 0.1kg to structural parts weighing 20kg, with an annual production capacity of over 5 million pieces.
· Process Parameters: The die casting pressure for aluminum alloy is 10-15MPa, the die casting speed for zinc alloy is 3-5m/s, and with a conventional exhaust system (non-vacuum die casting), the porosity is controlled within 1%.
3.Post-processing and Inspection
· Surface Treatment:
· Aluminum Alloy: Anodizing (salt spray resistance for 500 hours), powder spraying (film thickness 15-25μm).
· Zinc Alloy: Electroplating nickel/chromium (plating thickness 0.2-0.5μm), electrophoretic painting (glossiness > 80%).
· Inspection Equipment: Coordinate measuring machines (accuracy ±0.02mm), X-ray flaw detectors (defect recognition rate 99%), salt spray testers (simulating 1000 hours of corrosion resistance).
· Quality Control: Implementing the ISO 9001 standard, the full inspection rate ≥ 20%, and the defective product rate < 0.5%.
III. Core Application Scenarios
1.Automotive Parts
· Product Cases: Motor end covers (heat dissipation area increased by 30%), water pump casings (bearing capacity > 8MPa), and filter brackets (weight reduced by 15g).
2.Electronics and Home Appliances
· Typical Products: Mobile phone middle frames (alternative solutions with magnesium-aluminum alloy, cost reduced by 40%), laptop hinges (torque accuracy ±5%), and air conditioner compressor brackets (vibration attenuation rate > 20%).
· Technical Adaptation: Support RoHS/REACH environmental protection certification to meet the high-frequency iterative needs of the consumer electronics industry.
3.Industrial Equipment
· Application Examples: Hydraulic valve bodies (inner surface roughness Ra ≤ 1.6μm), reducer casings (gear meshing accuracy at IT8 level), and fixtures for automated equipment (repeat positioning accuracy ±0.05mm).
· Cost-performance Advantage: Replacing forgings, the material utilization rate is increased from 60% to 95%, and the processing cost is reduced by 30%.
IV. Cooperation Advantages
1.Cost Control
· Material Recycling: The recycling rate of waste aluminum/zinc > 95%, and the cost of recycled materials is 20% lower than that of new materials.
2.Delivery Capability
· Quick Response: Mass production can be carried out within 7-15 days after the sample is confirmed, and the emergency order can be shortened to 5 days.
3.Technical Support
· DFM Analysis: Provide free product manufacturability evaluation and optimize the structural design to reduce costs.
· After-sales Guarantee: The quality guarantee period is 1 year, and free repair services for defective parts are provided.
V. Frequently Asked Questions
Q1: What is the minimum order quantity for die castings?
A: The minimum order quantity for regular orders is 1000 pieces. For special requirements, small-batch trial production can be negotiated (such as 500 pieces).
Q2: What are the environmentally friendly options for surface treatment?
A: Chromium-free passivation (for zinc alloy) and water-based paint (for aluminum alloy) are recommended.
Q3: How to control the dimensional accuracy of die castings?
A: Use high-precision molds (tolerance ±0.05mm), and cooperate with full inspection by a coordinate measuring machine. The CPK of key dimensions ≥ 1.33.
Q4: Is the delivery cycle flexible?
A: The delivery cycle for standard orders is 20-30 days, and a flexible payment method of 50% advance payment + 50% final payment is supported.
We focus on process optimization and cost control, providing reliable, efficient, and economical solutions for hardware die castings in fields such as automotive parts, electronics, and industrial equipment.
Contact Yuyao Huantong Metal Products Co., Ltd. immediately to obtain a free DFM analysis and quotation plan - providing technical support throughout the process from drawing optimization to mass delivery, making your products more competitive in the market!
