Die Cast Gasoline Engine Part

Die casting is the process where molten metal is injected into a mold under high pressure in the range of 10 – 210 Mpa. This will result in a highly uniform casting with very good surface finish and exceptional dimensional accuracy. Usually this can either eliminate or greatly reduce the machining required to finish the part.

We can offer both the cold chamber process and the hot chamber process. In the cold chamber process the metal is ladled into the injection chamber for each shot. There is less exposure of the molten metal to the chamber walls and plunger. This is very useful for aluminum and copper alloys that would easily alloy with iron at elevated temperatures. The hot chamber process has the injection chamber which is connected to the die cavity permanently immersed in the molten metal. The hot chamber process is used for metals of low melting point and high fluidity such as tin and zinc.

Minimum wall thickness and draft angles for die castings are as follows:
Material Min. Thickness Min. draft angle
Aluminum 0.9 mm ( .035 in ) 0.5 degrees
Zinc alloys 0.6 mm ( .025 in ) 0.25 degrees
Copper 1.25 mm ( .050 in ) 0.7 degrees

The materials that Donrex offers are alloys of aluminum, copper, zinc and magnesium. Zinc castings can be made with thinner wall thickness than aluminum due to high melt fluidity.

We can produce parts from very small to about 15 kg (33 lbs ) for aluminum, 10 kg ( 22 lbs ) for magnesium, 25 kg ( 55 lbs ) for zinc and 5 kg ( 11 lbs ) for copper.