Molten magnesium alloy (approximately 650–700°C) is injected into the cavity of a steel die via a die-casting machine under high pressure (typically 30–100 MPa) and at high speed, rapidly filling the mold and solidifying to form the part. Magnesium high-pressure die casting is currently the most widely used and mature forming process for magnesium alloy components. Molten magnesium alloy is injected into the cavity of a steel die via a die-casting machine under high pressure and at high speed, rapidly filling the mold and solidifying to form the part.
Magnesium Die Casting in Innovaw
Our high-pressure magnesium die-casting production line consists of six cold-chamber die-casting machines equipped with closed-loop melting and feeding systems. Machine tonnages range from 280 metric tons to 1,000 metric tons. Brands include Yizumi and L.K.
Our magnesium alloy die-cast products cover automotive parts, telecommunications equipment, robots, 3C electronics components, LED lighting components, and sports equipment. Product dimensions range from 10 x 20 mm to 800 x 1,100 mm, and weights range from 10 g to 20 kg.
Material Scope：
Magnesium:
AZ91D, AM60B, AM50A, ZE41A
To better provide customers with one-stop services, Innovaw continues to invest heavily in research and development in the field of magnesium die casting. This includes introducing state-of-the-art high-pressure magnesium die casting equipment and conducting research into magnesium alloy semi-solid forming technology. Through continuous practical application, we are constantly refining the details of our magnesium alloy die casting processes, striving for continuous improvement.
What Is Magnesium Die Casting (MDC)?
High-pressure die casting (HPDC) is a manufacturing process in which molten metal is injected into a steel mold, or die, at high pressure and speed. It is widely used for creating precise, high-quality metal components with excellent surface finishes and complex geometries. This process is commonly applied in the production of parts made from lightweight metals like aluminum, magnesium, and zinc.
1. Key Characteristics
High Pressure: Molten metal is injected into the die under pressures ranging from 1,500 to 30,000 psi (10 to 200 MPa). This ensures the material fills all details of the mold.
Rapid Production: HPDC allows for short cycle times, often less than a minute, making it ideal for mass production.
Complex Geometries: The process enables the creation of intricate shapes with tight tolerances and smooth surfaces.
Thin Walls: Components can be produced with thinner walls compared to other casting methods, reducing material usage.
Surface Quality: The resulting parts have high-quality finishes, often reducing or eliminating the need for secondary machining or polishing.
2. The Process of HPDC
Die Preparation: The steel mold is cleaned and lubricated to ensure smooth metal flow and part ejection.
Metal Injection: Molten metal is injected into the die cavity at high speed and pressure.
Solidification: The metal cools and solidifies quickly within the mold, aided by water or oil cooling systems.
Ejection: Once solidified, the part is ejected from the die.
Trimming and Finishing: Excess material (flash) is removed, and additional finishing processes, if needed, are applied.
3. Advantages of HPDC
High Precision: Produces components with tight dimensional tolerances.
Efficiency: Low per-part cost in high-volume production.
Material Savings: Minimal waste compared to other casting methods.
Strength and Light Weight: Especially for aluminum and magnesium parts.
4. Common Applications of HPDC
Automotive Industry: Engine blocks, transmission cases, and wheels.
Electronics: Housings for laptops, smartphones, and cameras.
Consumer Goods: Components for appliances and furniture.
Aerospace: Lightweight structural parts.
5. Limitations of HPDC
Initial Costs: High tooling and equipment costs make it cost-effective only for large-scale production.
Material Limitations: Typically limited to non-ferrous metals due to die material constraints.
Size Constraints: More suited for small-to-medium-sized components.
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