HPDC Archives - High Pressure Die Casting Soulution Manufacturer 21 year experience | help die casting factories save time and money Mon, 04 Aug 2025 07:56:21 +0000 en-US hourly 1 https://wordpress.org/?v=6.9.4 https://acattech.com/wp-content/uploads/2025/07/cropped-ACATTECH-MOLD-LOGO-36454-32x32.png HPDC Archives - High Pressure Die Casting Soulution Manufacturer 32 32 The Status of Die-Casting Molds in Industry https://acattech.com/the-status-of-die-casting-molds-in-industry/ Thu, 28 Jan 2021 14:27:11 +0000 https://avadawebsites.wpengine.com/mechanic/?p=718 The Status of Die-casting Molds in Industry Molds are indispensable basic tools in manufacturing and an important symbol to measure the level of a country's manufacturing industry. Large die-casting molds that are complex, precise, and long-lived reflect the highest technical level. For a long time, developed countries such as Europe, America, and Japan have [...]

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The Status of Die-casting Molds in Industry

Molds are indispensable basic tools in manufacturing and an important symbol to measure the level of a country’s manufacturing industry. Large die-casting molds that are complex, precise, and long-lived reflect the highest technical level. For a long time, developed countries such as Europe, America, and Japan have implemented strict technological and standard blockades, and most of my country’s high-end die-casting molds rely on imported technologies.

The Status of Molds in Industry

  • “The mold industry is the cornerstone of American industry” (USA)
  • “Molds are the driving force for social prosperity” (Japan)
  • “Molds are the emperors in metal processing” (Germany)
  • “Molds are gold” (Romania)
  • “The mold industry is an ever-lasting industry” (Europe)
  • “The mold industry is the pearl in the palm of manufacturing” (Taiwan)
  • “Molds are efficiency amplifiers” (Singapore)
Molds are the mother of industry. 80% of the problems in the production process come from molds, so molds are the most important tools in our production.

Application Range of Die-Casting Molds

Die-casting molds involve more than 30 industrial fields such as aviation, automobile, motorcycle, electronic information and communication, municipal administration and lighting, energy, machinery, construction hardware, household appliances, and medical equipment. Most of people’s daily travel and communication tools, lighting, and home appliances are related to die-casting products produced by die-casting molds. The application range of die-casting products is second only to that of stamping and plastic products. Moreover, with the development of lightweight new energy vehicles in the future, die-cast aluminum and magnesium alloys will definitely enter a period of rapid growth, and their proportion in automobiles and other fields will increase year by year.
Although there are many types of molds, the commonly used molds in production are stamping dies, plastic molds, and die-casting molds. According to the data from the Mold Industry Association, stamping dies account for about 40% to 50% of the total mold quantity, injection molds account for about 20% to 30%, and other molds account for about 20% to 40%.
The automotive industry is the largest user of the mold industry:
  • A small car probably uses 8,000-15,000 molds.
  • A mid-range sedan probably uses 15,000-30,000 molds.

What is a Die-Casting Mold?

Die-casting is the abbreviation of pressure casting!
A die-casting mold is a mold used in the process where high-temperature molten or semi-molten metal is filled into the mold cavity at a high speed under high pressure and solidified quickly under pressure to obtain castings. The mold used in this process is called a die-casting mold.
  • Hot chamber die-casting molds
  • Cold chamber die-casting molds

Essential Factors and Production Process of Die-Casting Mold Production

Three essential factors for die-casting production: alloy raw materials, die-casting machines, die-casting molds.
Die-casting production process: melting materials → clamping mold → pressure die-casting → cooling and solidification → opening mold → taking out castings.

Applications of Die-Castings in the Automotive Field

Wiper system Engine system Filter system
Air conditioning system Shock absorption system Precision compressor parts
Power steering control system Brake control system (ABS) Rearview mirror system
Transmission Car seats Car wheels
Shock towers Chain covers Steering knuckles
Car suspension beams Oil pumps  ,etc.

Die-Castings in the Communication Field

Dual-tower amplifiers Mobile phone panels Chassis components Filters
Upper cover of portable signal devices Lower cover of portable signal devices Mobile phone middle frames Radiators, etc.

Die-Castings in the Computer Field

All-in-one machine back covers Laptop brackets Radiators Key panels
3-piece set of desktop computer hard disk enclosures Laptop bottom covers Screen frames Heat dissipation systems
LCD monitor bottom covers Laptop PCB brackets Bottom covers  ,. etc

High Pressure Die-Castings in the Lighting Field

Street lamp enclosures LED lamp covers Shields Radiators
Square lamp enclosures advertising lamp brackets Fixed plates  .,etc

Applications of Die-Castings in the Electrical Appliance Field and the Motor Field

Razor enclosures Handle enclosures Motor casings Motor covers
Rotating bases LED box brackets Motor end covers Upper motor covers
Office chair feet LED frames Micro motor casings Lower motor covers
Submarine driver enclosures Bar chairs Motor back covers Motor brackets
Cutting machine enclosures Meat grinders Rear end covers  ., etc

aCatTech R&D, Design, Manufacturing, and Batch Production Capabilities

During the vehicle R&D stage of the main engine factory:
We start from the initial concept of the customer’s product and cooperate closely with the customer to jointly evaluate the feasibility of product design and the batch stability of subsequent production.
  • Rapid prototype test molds: CAD and CAE auxiliary design and analysis to ensure the feasibility of the scheme.
  • We can assist main engine factories in the preliminary design and development and process evaluation of alloy parts and structural parts for the power section, and can also quickly develop die-casting molds for test prototypes, providing efficient services for the preliminary testing of the main engine factory’s entire vehicle.
  • Complete the production of complex rapid test molds within 5-6 weeks.
  • Small-batch production of rapid test prototypes can be completed in 3-5 days, providing main engine factories with the fastest parts that are closest to subsequent production.

For mass production, we have 22 sets die-casting machines. For more information, please contact us here

Benefits That aCatTech Technological Innovation Can Bring to Society

Motors are the source of power in the industrial field. They realize the mutual conversion of electrical energy and kinetic energy through the action of electricity and magnetism. Motors occupy a very important position in the global industrial automation market and are widely used in metallurgy, petrochemicals, electric power, coal, mining, building materials, papermaking, municipal administration, water conservancy, shipbuilding, port loading and unloading, and other fields.
The traditional method of making motor casings is to first die-cast an aluminum alloy blank with machining allowance, and then process the red surface through a lathe to meet the assembly requirements.
Through technological innovation, we optimize mold design and manufacturing, and achieve one-time die-casting forming, which can meet the assembly requirements without inner hole processing. The processing time for a single motor is reduced by at least 1 minute. If the annual demand for a single product is 100,000 units, it will reduce 100,000 minutes. Calculated at 10 cents  per minute, a single product can save at least 100,000 × 0.1 = $ 80,000 per year. If calculated based on 10,000 sets of motor molds per year, it will save more than 8 billion in processing costs.

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]]> HPDC Die Casting- Basic Principles https://acattech.com/hpdc-die-casting-basic-principles/ Thu, 28 Jan 2021 14:24:07 +0000 https://avadawebsites.wpengine.com/mechanic/?p=715 Basic Principles of Die Casting Table of Contents​ Basic Principles and Characteristics of Die Casting​ Common Fluid Principles and Applications​ Overview of Liquid Metal Filling Theory​ Flow State and Characteristics of Liquid Metal Die Casting Process Cycle​ Semi-automatic die casting cycle: Clean the mold → Spray → Place inserts → Close the mold [...]

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Basic Principles of Die Casting

Table of Contents​
  • Basic Principles and Characteristics of Die Casting​
  • Common Fluid Principles and Applications​
  • Overview of Liquid Metal Filling Theory​
  • Flow State and Characteristics of Liquid Metal
Die Casting Process Cycle​
  • Semi-automatic die casting cycle: Clean the mold → Spray → Place inserts → Close the mold → Pour material → Inject → Cool and solidify → Open the mold → Eject → Take the part​
Automatic die casting cycle: (Same steps as semi-automatic)
Conditions Related to Die Casting Production​
  • Die casting design: Requirements (performance, appearance); Structure (fillets, draft angles, wall thickness, holes); Gating system design​
  • Die casting machine: Clamping, injection, ejection, feeding (pressure, speed, cycle actions); Maintain precision; Capability requirements (preheating, cooling)​
  • Die casting operation: Keep in normal state; Coating (type, spray amount); Die casting cycle; Mold temperature​
  • Die casting process: Specific pressure, filling speed, filling time; Process parameters​
  • Mold: Material and heat treatment; Machining accuracy; Design; Maintenance​
  • Alloy material and melting: Furnace charge ratio; Alloy composition; Flux usage; Temperature control; Cleanliness (gas, hard spots, foreign matter); Ratio of return material​
  • Die caster: Safe operation; Professional knowledge; Proficiency; Dedication; Physical strength
Application of Pascal’s Principle​
Ap — Punch cross-sectional area;​
Ph — Die casting machine accumulator pressure;​
Ah — Injection cylinder cross-sectional area;

Injection Pressures for Various Alloys

Alloy Injection Pressure / MPa
Zinc alloy 20~30
Aluminum alloy 30~80
Magnesium alloy 30~70
Copper alloy 50~80

Gate Speed Based on Wall Thickness

Wall Thickness (mm) Gate Speed (m/s)
-0.8 46-55
1.3-1.5 43-52
1.7-2.3 40-49
2.4-2.8 37-46
2.9-3.8 34-43
4.6-5.1 32-40
6.1 28-35

Overview of Liquid Metal Filling Theory

Theory of Jet Filling

Filling forms of molten metal in the cavity:

  • (a) Impacting the mold wall;
  • (b) Backflow;
  • (c) Accumulating at the far end of the cavity;
  • (d) Accumulating in the middle of the cavity

Theory of “Full Wall Thickness” Filling

Filling forms of full wall thickness filling theory:
  • (a) Entering the cavity;
  • (b) Starting to expand;
  • (c) Expanding to the mold wall;
  • (d) Filling forward;
  • (e) Filling to the mold wall;
  • (f) Filling the cavity

Theory of “Three-Stage” Filling

It affects the surface quality of die castings, the hardness of die castings, and the strength of die castings.
Filling forms of three-stage filling theory:
  • (a) Forming a thin shell layer;
  • (b) Continuing to fill;
  • (c) About to be full;
  • (d) Forming a closed hydraulic system after filling the cavity

Factors Affecting Die Casting Metal Flow

  • High-speed injection of molten metal; Low-speed injection of molten metal
  • Parting surface: Moving mold, fixed mold
  • Filling forms of metal flow at cavity corners:
    (a) Entering the cavity; (b) Generating eddy currents at corners; (c) Filling the vertical part; (d) Filling to the left
  • Filling forms of molten metal at arc surfaces:
    (a) Entering the cavity; (b) Flowing to the outer mold wall; (c) Flowing close to the outer mold wall
    1–Molten metal; 2–Trapped air

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]]> Scuffing in High-Pressure Die Casting Molds https://acattech.com/scuffing-in-high-pressure-die-casting-molds/ Thu, 28 Jan 2021 14:09:43 +0000 https://avadawebsites.wpengine.com/mechanic/?p=712 As aCatTech, specializing in high-pressure die casting molds and casting production for the automotive sector, we have gained profound insights through years of practice that scuffing and heat checking are common and challenging issues in high-pressure die casting mold production. These issues not only affect casting quality but also shorten mold lifespan and increase [...]

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As aCatTech, specializing in high-pressure die casting molds and casting production for the automotive sector, we have gained profound insights through years of practice that scuffing and heat checking are common and challenging issues in high-pressure die casting mold production.

These issues not only affect casting quality but also shorten mold lifespan and increase production costs. Based on our experience, we will elaborate on the causes, prevention strategies, emergency treatment, and lifespan restoration solutions for these two major issues, and provide professional recommendations.

Scuffing in High-Pressure Die Casting Molds

In the high-pressure die casting production of automotive components, mold scuffing is a frequent issue encountered by aCatTech. Through extensive practical summary, we have identified the main causes as follows.

Core Cause Analysis of Scuffing Issues​
  1. Mold Design Defects​
In our production practice, we have repeatedly encountered scuffing caused by mold design flaws. For example, insufficient draft angles (less than the industry standard of 3°, or even negative draft angles) directly lead to significantly increased ejection resistance, thereby causing scuffing. When cavity surface roughness exceeds standards (Ra > 0.8μm), micro-protrusions form mechanical interlocking points, resulting in scuffing during ejection. Improper fit clearance of inserts/slides—clearance < 0.02mm easily causes extrusion scuffing, while clearance > 0.1mm leads to flash tearing and subsequent scuffing.​
  1. Material and Processing Issues​
We have found that insufficient die steel hardness (HRC < 46) accelerates surface wear, easily forming erosion grooves and causing scuffing. Improper heat treatment leading to surface decarburization reduces the mold’s anti-adhesion properties, increasing the likelihood of scuffing. Additionally, unpolished EDM (Electrical Discharge Machining) surfaces leave residual discharge erosion marks, which serve as starting points for scuffing—this has been repeatedly verified in our production.​
  1. Improper Process Parameters and Maintenance​
Excessively high injection speeds (> 50m/s) cause molten metal to scour the cavity at high speed, resulting in surface damage and subsequent scuffing. Uneven or ineffective release agent spraying leads to local lubrication loss, causing sticking and scuffing. Insufficient mold preheating (< 150℃) exacerbates cooling shrinkage of molten metal, increasing ejection resistance and scuffing risks.

Design of Systematic Prevention Measures

  1. Design Stage Optimization​
In the design phase, aCatTech uses CAE simulation for the ejection process to ensure critical draft angles ≥ 5°, reducing ejection resistance from the source. For scuffing-prone areas (e.g., deep cavities, thin-walled structures), we install removable inserts for easy later maintenance and replacement. Meanwhile, we strictly control cavity surface roughness to Ra ≤ 0.4μm and mating surface precision to IT6 grade, reducing the formation of mechanical interlocking points.​
  1. Material and Manufacturing Control​
We select high-quality hot-work die steels such as H13 and 8407, and reduce sulfur content (≤ 0.005%) through electroslag remelting to enhance die steel performance. In heat treatment, we perform high-temperature quenching (1050℃) + triple tempering (560℃) to control surface hardness at HRC 48-52, enhancing mold wear resistance. After finishing, mirror polishing is conducted to completely eliminate machining marks and avoid scuffing initiation points.​
  1. Production Process Control​
During production, we implement staged control of injection speed: ≤ 30m/s in the filling stage and ≥ 80m/s in the boosting stage to reduce molten metal erosion on the cavity. Water-based release agents (5%-8% concentration) are used with automatic spraying systems to ensure uniform coverage and effective lubrication. Molds are preheated to 180-220℃, and oil temperature machines maintain mold temperature fluctuations ≤ ±10℃ to reduce scuffing caused by temperature changes.

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]]> Heat Checking in High-Pressure Die Casting Molds https://acattech.com/heat-checking-in-high-pressure-die-casting-molds/ https://acattech.com/heat-checking-in-high-pressure-die-casting-molds/#respond Wed, 09 Sep 2015 19:15:50 +0000 https://avadawebsites.wpengine.com/classic-shop/?p=16378 Formation Mechanism and Pre-emptive Prevention of Heat Checking in High-Pressure Die Casting Molds Heat checking is another common and severe issue in high-pressure die casting molds. Through long-term production and research, aCatTech has developed a deep understanding of its formation mechanism and prevention measures. Three-Stage Model of Heat Checking Development and Key Triggers​ [...]

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Formation Mechanism and Pre-emptive Prevention of Heat Checking in High-Pressure Die Casting Molds

Heat checking is another common and severe issue in high-pressure die casting molds. Through long-term production and research, aCatTech has developed a deep understanding of its formation mechanism and prevention measures.

Three-Stage Model of Heat Checking Development and Key Triggers​
  1. Crack Initiation Stage (Stage I)​
In this stage, non-metallic inclusions at grain boundaries (e.g., sulfides, oxides) cause stress concentration, triggering microcracks (size < 50μm) under thermal cycles (temperature difference > 300℃). We have observed that carbide segregation or aggregation reduces grain boundary bonding strength, forming initial crack sources—this is frequently noted during mold inspection and analysis.​
  1. Crack Propagation Stage (Stage II)​
Untreated microcracks, under the impact of high-pressure (> 100MPa) molten metal, connect along grain boundaries or interdendritic regions to form visible heat checking (width 0.1-0.5mm). Meanwhile, high-temperature softening of die steel (hardness reduction > 15% at > 500℃) accelerates lateral crack propagation, posing a significant threat to mold lifespan.​
  1. Structural Failure Stage (Stage III)​
When the heat checking network penetrates, local strength loss occurs, leading to mold collapse or penetration. Our statistical data shows that typical failure locations concentrate in thermal stress concentration areas such as near gates and around cooling water channels.

Construction of Full-Cycle Prevention System

  1. Material Performance Enhancement​
We select high-purity die steels (purity grade ≥ A0.5) and strengthen grain boundaries by adding zirconium and boron (0.01%-0.05% content). Vacuum heat treatment is adopted to eliminate internal pores and structural defects, improving the mold’s thermal fatigue resistance—this is a key measure in our material selection and processing.​
  1. Design and Structural Optimization​
In design, we avoid sharp angles (minimum R angle ≥ 3mm) and use hyperbolic flow-guiding structures in critical transition areas to reduce stress concentration. Cooling water channels are maintained at 3-5 times the hole diameter from the cavity surface to avoid local overheating. For heat checking-prone areas (e.g., parting surfaces, core roots), stress relief grooves are added—an effective design method verified through repeated practice.​
  1. Usage and Maintenance Strategies​
We have established strict mold preheating curves: heating rate ≤ 10℃/min with 2-hour insulation to avoid sudden temperature changes. Stress relief annealing (520℃ × 4 hours) is performed every 5,000 cycles to eliminate accumulated thermal stress. Cavity surfaces are inspected regularly (weekly) using fluorescent testing to detect early cracks, enabling early detection and treatment.

Emergency Treatment Technologies and Lifespan Restoration Solutions for Scuffing and Heat Checking

Timely and effective treatment is crucial when molds develop scuffing or heat checking. aCatTech has accumulated rich experience in emergency treatment and restoration.​
(I) Rapid Repair Strategies for Scuffing Issues​
  1. Minor Scuffing (Depth < 0.2mm)​
For minor scuffing, we use diamond grinding heads to refine damaged areas, paired with 1000# and finer sandpaper for polishing, restoring surface roughness to Ra ≤ 0.8μm. Meanwhile, local application of molybdenum disulfide coating (5-10μm thickness) enhances anti-adhesion performance. Such treatment typically restores normal mold functionality.​
  1. Moderate Scuffing (Depth 0.2-0.5mm)​
For moderate scuffing, EDM deposition repair is adopted using H13 welding wires. After repair, local quenching (induction heating to 950℃) + low-temperature tempering (200℃) is performed to restore hardness to HRC 46-48. After grinding, draft angle compensation (1°-2° increase) is applied to reduce re-scuffing risks.​
  1. Severe Scuffing (Depth > 0.5mm or Large-Area Damage)​
For severe scuffing, if the mold has removable inserts, we replace them using shrink fitting (interference 0.02-0.05mm) to ensure positioning accuracy. If insert replacement is impossible, the entire cavity is ground (removal ≥ 1mm) and re-nitrided (case depth 0.3-0.5mm) to maximize mold performance restoration.

Graded Repair Technologies for Heat Checking Defects

  1. Early Heat Checking (Crack Length < 10mm, Depth < 0.3mm)​
For early heat checking, laser cladding technology (power 1.5-2.0kW) is used, with cladding layer composition matching the die steel. After cooling, ultra-precision grinding is performed. Post-repair low-temperature tempering (180℃ × 2 hours) eliminates laser processing stress, ensuring good mold lifespan after repair.​
  1. Mid-Stage Heat Checking (Crack Length 10-50mm, Depth 0.3-1.0mm)​
For mid-stage heat checking, the cracked area is milled out (2mm expansion), and EDM build-up welding is applied (layered welding, each layer ≤ 0.5mm thickness). Post-welding high-temperature tempering (560℃ × 3 hours) is conducted. Coordinate grinding machines refine the profile with precision controlled within ±0.01mm to ensure mold accuracy.​
  1. Deep Heat Checking Repair and Lifespan Extension​
For deep heat checking, the entire mold undergoes secondary quenching (heating rate 5℃/min, holding time calculated by thickness) with high-pressure gas quenching. PVD coating (TiN/TiCN, 3-5μm thickness) is applied to enhance thermal fatigue and erosion resistance. After repair, a dedicated usage plan is formulated, limiting cycles ≤ 20,000 with enhanced monitoring to ensure production safety.

Post-Repair Performance Verification and Continuous Monitoring

  1. Quality Inspection​
After repair, 3D scanners (precision ±0.02mm) are used to inspect profile dimensions, ensuring draft angles and roughness meet design requirements. Hardness testers (10kg load) sample repair areas, with hardness deviation ≤ ±2HRC to guarantee repair quality.​
  1. Production Verification​
First-piece production involves continuous test runs of 50 cycles, observing casting surface quality (scuffing grade ≤ 1, no new heat checking). Mold temperature and injection pressure data are collected every 200 cycles, and a thermal stress early warning model for crack-sensitive areas is established (threshold ≥ 80MPa) to detect potential issues promptly.

Recommendations for Customers

  1. In the early stage of mold design, we recommend full communication with aCatTech. We will provide professional mold design solutions based on your product characteristics and production needs, reducing scuffing and heat checking risks from the source.​
  1. Select high-quality mold materials and strictly follow our material standards for procurement and inspection to ensure material performance meets requirements.​
  1. During production, strictly adhere to our formulated process parameters and maintenance strategies. Regularly inspect and maintain molds to detect and address potential issues promptly.​
  1. When molds develop scuffing, heat checking, or other issues, we recommend contacting us promptly. Based on the mold damage, we will provide professional repair solutions to maximize mold lifespan and reduce production costs.​
Through the above full-process technical solutions from prevention to remediation, aCatTech is committed to providing systematic solutions for high-pressure die casting molds in the automotive sector. While controlling defect risks at the source, we maximize mold lifespan through efficient repair technologies, helping customers achieve both quality and efficiency improvements.

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