Copyright 2024 © Dongguan KAIYAN
KAIYAN specializes in providing excellent die casting services. The company has advanced die casting equipments which can precisely control the parameters of pressure, speed and temperature to ensure the die casting process is stable and efficient. Whether it is aluminum alloy, zinc alloy or magnesium alloy, all of them can be processed according to customers’ demands. The mold design team has strong ability and rich experience, the design and production of high quality molds, long service life, high precision to ensure that the product size is accurate and high quality. In terms of surface treatment, we cover a variety of processes such as polishing, electroplating, sandblasting, etc., which give our products excellent appearance and protective performance. Adhering to the strict quality control system, following a number of international certification standards, with efficient production and quality service, to meet the automotive, electronics, machinery and other fields of customized die-casting needs of customers.
Die castings have obvious advantages in the manufacturing industry and are the preferred method of manufacturing metal parts in various industries:
High precision and complex shape manufacturing ability: general tolerance grade can reach IT13 ~ IT15, higher precision can reach IT10 ~ IT11. can make complex shape parts, very suitable for high quality parts of mass production.
High productivity: Due to the high speed filling and rapid cooling of molten metal, the production cycle is very fast, and it is easy to realize automated production, so it is possible to make a large number of parts quickly and improve the production efficiency.
Low scrap: High material utilization efficiency produces minimal scrap, which reduces waste and usually reduces the need for secondary processing, thus lowering costs.
Excellent mechanical properties: the metal liquid is injected into the mold cavity under high pressure and rapidly cooled and crystallized, making the surface of the die-casting parts of the grain is fine and dense, the internal organization is uniform, so as to have high strength, hardness and wear resistance.
Aluminum is lightweight and hard, so it is ideal for use in goods that require durability and minimize weight, such as automobiles and airplanes.
Zinc die castings have high strength, hardness and wear resistance. It is capable of precise, high-tolerance die casting for complex designs and durable components, such as automotive engine parts, mechanical transmission parts, etc.
Magnesium has a density of about 1.74 g/cm³, the lightest of all practical metals, with excellent specific stiffness (ratio of stiffness to weight), magnesium and magnesium alloys are widely used in aerospace, automotive and other fields for the manufacture of weight-reducing components.
Copper alloy has high modulus of elasticity, copper die casting products have high strength, high hardness and wear resistance, very suitable for some gears, bearings and so on.
Enhances the surface smoothness and gloss of metal castings and reduces surface roughness to achieve a visually attractive, high gloss surface finish.
Electroplating can make the surface of parts with corrosion resistance and oxidation resistance, which is a process of plating a metal film on the metal surface by using the principle of electrolysis. For aluminum alloy die castings, traditional aqueous plating solutions cannot effectively plate aluminum due to its high activity. Therefore, aluminum plating needs to be carried out with special organic solvents or ionic liquids.
A uniform matte finish can be achieved by blasting the surface with fine particles, which also helps to remove minor imperfections (burrs and other surface defects), improve surface roughness and prepare the surface for subsequent surface treatments.
Anodizing can not only enhance the corrosion resistance of aluminum alloy die castings processed by aluminum die castings, but also change the surface color by adjusting the process parameters to increase the aesthetics of the products.
Spraying (painting or powder coating) is a method of applying paint to the surface of the object to be coated by dispersing the paint into uniform and fine droplets by means of pressure or centrifugal force by means of a spray gun or disc atomizer. This method is applicable to die castings of various materials and provides good coverage and color selection.
Creates a unique look with a fine line pattern on the metal surface, helping to hide fingerprints and minor scratches for both beauty and utility.
The parameters of KAIYAN machined parts are presented in a detailed table with key performance and quality indicators.
| Description | |||||
| Minimum part mass | 0.015 kg | ||||
| Maximum part mass | 20kg | ||||
| Minimum part volume | 1㎤ | ||||
| Maximum part volume | 20000㎤ | ||||
| Minimum wall thickness | 0.8 mm | ||||
| Maximum wall thickness | 12.7 mm | ||||
| Surface roughness | Ra0.8μm~Ra6.3μm | ||||
| Minimum Customized Volume | 1000 pcs | ||||
| Quality Control | ISO 9001 Certified |
Die casting process is a versatile manufacturing process that is widely used in various industries due to its high precision, reliability, fast molding speed and high degree of automation. The following are some of the main application areas:
Automotive industry: commonly used in the manufacture of engine blocks, cylinder heads, pistons, intake manifolds, oil sumps and other parts. This is because die casting can meet its durability requirements as well as strict tolerance standards.
Hardware industry: such as furniture hinges, handles, locks, rails, etc., alloy die casting die casting process can produce a variety of styles, reliable quality products.
Electronic equipment industry: used in the manufacture of smart phones, laptops, heat sinks and cameras and other electronic products in the strong and complex structure of the parts.
Medical Device Industry: Precision die casting is used to produce high-precision instruments and device parts, which are essential for reliability and sterility in the medical field.
Toys and decorations industry: die casting process can quickly and efficiently produce a variety of complex shapes, high precision toy models, such as toy cars, robots, dolls and so on. In the decorative industry can produce exquisite shape, rich details of jewelry boxes, handicraft ornaments, etc..
Machinery manufacturing industry: including gears, bearings, bushings, pump body, valve body, etc.. Die casting process can make these parts have the right strength, hardness, wear resistance and dimensional accuracy.
KAIYAN has high efficiency and fast production. With the latest automated equipment, we are able to meet your needs and shorten the lead time to customize complex shapes for die casting.
KAIYAN provides precision die casting services by having a professional quality inspection team that conducts comprehensive quality checks before production, during production, first piece inspection and before shipment.
KAIYAN is an expert in customized die casting solutions that increase durability and reduce costs. Our advanced technology and manufacturing facilities ensure that every component is of high quality, functional and aesthetically pleasing.
Die casting process is suitable for the production of a variety of complex shape, high dimensional accuracy requirements of metal parts. For example, automobile engine block, cylinder head, transmission shell, electronic equipment shell, radiator, and a variety of hardware accessories, toy models and so on.
Vibration of the die-casting machine itself, mechanical components are not balanced, hydraulic system problems, equipment installation foundation is not solid, mold structure is not reasonable
The moving mold and the fixed mold are not close together.
According to the different tolerance of the material is different, usually divided into the following kinds:
Zinc alloy: in general, for the size of 18mm below the die casting, the tolerance can be controlled in ± 0.07mm; 18-30mm size, the tolerance is ± 0.08mm; 30-50mm size, the tolerance is ± 0.10mm.
Aluminum and magnesium alloys: for sizes up to 18 mm, the tolerance is usually ±0.11 mm; for sizes 18-30 mm, the tolerance is ±0.13 mm; for sizes 30-50 mm, the tolerance is approximately ±0.16 mm.
Copper alloys: Tolerances for copper alloy die castings are typically ±0.18mm for sizes up to 18mm, ±0.21mm for sizes 18-30mm, and ±0.25mm for sizes 30-50mm.
The lead time for mold design and manufacturing varies depending on the complexity and size of the mold, but our company has an excellent engineering team that can deliver in a time frame that is satisfactory to the customer.
Die casting design should consider the use of the product scene required strength, hardness, toughness, etc., but also consider the accuracy of the product, physical properties (thermal conductivity, electrical conductivity), etc., in order to meet these conditions at the same time should also take into account the cost of production as well as production efficiency issues.
KAIYAN has a strict quality inspection system, from the use of raw materials, the processing process have professional quality inspection personnel for testing and monitoring, while high-quality molds are also the key to ensure quality.
Copyright 2024 © Dongguan KAIYAN