Hot Casting
(Hot Chamber Die CAsting)
Hot casting is one of two primary die casting techniques used to produce dimensionally accurate, defined metal parts from non-ferrous metals. This casting method creates parts from zinc, magnesium, tin, and other low melting point alloys.
Hot Chamber Die Cast MANUFACTURing
Redstone Manufacturing offers hot chamber casting services at three manufacturing locations including China, Mexico, India, Taiwan, and Brazil. Hot casting has applications in industrial products such as heavy machinery, gears, construction materials, and even vehicles. Component design flexibility and material options combined with production efficiency make it a favorable manufacturing method worldwide.
Hot Chamber (Hot Casting) DIE CASTING Process
During the casting process, molten metal is forced into a steel die under high pressure. The part is allowed to cool fully, then it is ejected from the die, and the process starts all over again. The defining feature of hot chamber die casting is that metal ingots are heated in a pot that is part of the entire casting machine versus in a separate furnace. Once metal reaches a liquid state, a piston pushes the metal from the furnace, through a gooseneck, and into the die at high pressures.
Advantages of Hot Chamber Die Casting
- Rapid production with an avg. of 15-20 cycles per minute.
- Ability to cast highly detailed parts.
- Reduced porosity compared to high melting point metals.
- Longer casting die life – dies do not degrade under low melting point metals.
Disadvantages of Hot Chamber Die Casting
- Limited to low melting point metals – high melting point and corrosive alloys erode the melting pot, cylinders, and plunger.
- Cannot cast aluminum because it reacts with lead in the machine’s molten metal reservoir.
What Metals are Used for Hot Casting?
Hot chamber die casting can only be used with lower melting point alloys because of the machine’s setup. Certain portions of the casting machine that are immersed in a molten metal can not withstand the high temperatures required to heat certain metals. These alloys have melting points between 600°F and 1200°F. Additionally, aluminum cannot be cast with this method because its corrosive nature will damage the melting pot.
Zinc Alloy
Hot Casting
Zinc is one of the most versatile alloys used in manufacturing. Zinc has lower material costs; it is strong, corrosion-resistant, and both electrically and thermally conductive. These alloys will have varying ratios of zinc, magnesium, aluminum, and copper.
Copper Alloy
Hot Casting
Alloys with nominal copper can be cast with this method because their melting point is 1,984°F. Copper has some of the highest mechanical properties of all die-cast alloys. It comes at a higher price per pound but has excellent dimensional stability, wear resistance, and strength that approaches steel parts.
Lead Alloy
Hot Casting
Applications that require less than 8000 pounds of tensile strength typically use lead alloys for hot chamber die casting. Lead is usually inexpensive when compared to other materials, and it offers good corrosion resistance under a variety of conditions.
Magnesium Alloy
Hot Casting
Magnesium is the base material for many alloys. It is incredibly lightweight, has good castability, and is easy to machine.
Tin Alloy
Hot Casting
Tin is used as a base in parts that require high corrosion resistance. Tin alloys used in casting typically contain 90% tin, 6% Antimony, and 4% copper.
companies using our hot casting process:
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Changed from Brochure to Newsletter on 8/12/24