High pressure die casting

At Nutec Bickley we design and manufacture custom electric and gas furnaces for the heat treatment of non-ferrous parts for HPDC processes.

Contact us

The basic die casting process consists of injecting molten metal (often aluminum or zinc alloys) under high pressure into a steel mold called a die. Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die. Typically, machine sizes range from 400 tons to 4000 tons. Regardless of their size, the only fundamental difference in die casting machines is the method used to inject molten metal into a die.

The two methods are hot chamber or cold chamber. A complete die casting cycle can vary from less than one second for small components weighing less than a gram, to two or three minutes for a casting of several kilograms, making die casting the fastest technique available for producing precise non-ferrous metal parts.

Robotic cells and ultra-high pressure casting techniques have been introduced in recent years.

ADVANTAGES OF THE HIGH PRESSURE DIE CASTING PROCESS

  • Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can gain a number of advantages and benefits by specifying die cast parts.
  • High-speed production: Die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.
  • Dimensional accuracy and stability: Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. The parts are also heat resistant.
  • Strength and weight: Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are stronger and lighter than those possible with other casting methods. Additionally, because die castings do not consist of separate parts welded or fastened together, the strength is that of the alloy rather than the joining process.
  • Multiple finishing techniques: Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or finished with a minimum of surface preparation.
  • Simplified assembly: Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes; alternatively, external threads can be cast.

Furnaces we manufacture for High pressure die casting heat treatment

Some typical operations might incorporate our roller hearth or basketless carousel furnaces/ovens. Where solution treatment is needed, we can fabricate custom designed water and air quench systems.

Solution heat treating generally takes place up to a maximum temperature of 600°C/1110°F, and for aging around 260°C/500°F.


Roller hearth furnaces

Nutec

Roller hearth ovens and furnaces are designed for batch process applications, and for indexing–continuous production.

View More

Basketless Heat Treat OVENS

Nutec

Nutec Bickley’s Basketless Heat Treatment Systems are designed for the heat treatment of aluminum castings and forgings.

VIEW MORE

Nutec

Download our furnaces e-book covering all metals industry sectors!

Great temperature uniformity, performance and quality are some of the characteristics that make us the best designers and manufacturers of furnaces and ovens available in the market.

Download

Advantages of Nutec Bickley Systems

Nutec Bickley has extremely wide experience in the design, manufacture and commissioning of industrial furnaces, particularly for high temperature operations. We work closely with the customer to achieve a design tailored to the exact requirements of each factory. We undertake all fabrication work at our Monterrey headquarters, including complete manufacture and testing of the furnace. Customers are encouraged to participate at every stage and are welcomed to our facility to inspect progress.

Nutec Bickley is an internationally recognized supplier of advanced systems to the automotive industry, and some die casting takes place here.

We offer expert technical support in all these areas.

Industries and applications of HPDC

Alloy A380 (ANSI/AA A380.0) is by far the most widely cast of the aluminum die casting alloys, offering the best combination of material properties and ease of production. It may be specified for most product applications.

Some of the industries that use this alloy are:

Automotive components
Electronic and communications equipment
Engine brackets
Transmission and gear cases
Appliances
Lawn mower housings
Furniture components
Hand and power tools

In this demanding sector, Nutec Bickley has references including a major international castings supplier to OEMs; a world leading producer of aluminum cylinder heads and engine components; a manufacturer of innovative lightweight components; and all the principal automotive parts suppliers.

Types of heat treatment in HPDC

Aluminum castings don’t generally receive solution heat treatment, but are usually aged. Low-temperature aging treatments may be used for stress relief or dimensional stability. A T2 or T5 temper may be given to improve properties. Because of the rapid cooling rate and ultra-fine grain size in die castings, the structure once the piece is cast resembles solution heat treatment T4 and T5 temper results in properties quite similar to those which might be obtained if given a full T6 temper.

As stated above, aluminum alloy die castings are not usually heat treated; however, there are heat treatable specialty alloys available for structural applications, such as the Silafonts and AA365. Die castings are not generally gas or arc welded, or brazed; however, developments in high integrity die casting processes coupled with specialty alloys has enabled the successful welding of die castings in specific applications.

NEED HELP?

You can contact us by email: sales@nutec.com

Or send us a message describing your project and we’ll help you get a better result

CONTACT US