Die-casting aluminum parts is one of the excellent metal forming methods. It is a way to achieve fewer chips and no chips. It is widely used and developed rapidly. The wall thickness of die-casting aluminum parts (usually called wall thickness) is a factor of special significance in the die-casting mold process. The wall thickness is closely related to the entire process specification, such as the calculation of filling time, the selection of innate speed, and the calculation of solidification time. , Analysis of the temperature gradient of the mold, the effect of pressure (final specific pressure), the length of the mold retention time, the temperature of the ejection of the casting, and the operating speed, etc.
At present, die-casting alloys are no longer limited to non-ferrous metals such as zinc, aluminum, magnesium, and copper, and are gradually expanding to be used for die-casting cast iron and steel castings. The size and weight of die-cast aluminum parts depend on the power of the die-casting machine. As the power of the die-casting machine continues to increase, the size of the casting can range from a few millimeters to 1-2m; the weight can range from a few grams to tens of kilograms. It can die-cast aluminum parts with a diameter of 2m and a weight of 50kg. In die casting, what are the effects of the wall thickness of aluminum die castings of different sizes?
Effect of the too-thick wall thickness of aluminum die casting
- Surface quality: If the wall thickness of aluminum die castings is too thick, the surface quality will be poor, and defects such as rough appearance, burrs, and bubbles will occur frequently, which cannot meet the high-demand appearance requirements.
- Decreased tensile strength: If the wall thickness of aluminum die casting is too thick, the tensile strength of the material will decrease, because the aluminum material shows a tendency to plastic deformation, and the greater the thickness, the further reduction in the availability of the aluminum material.
- Poor machinability: If the wall thickness of the aluminum die casting is too thick, the processing difficulty will increase, because the aluminum material that is too thick is difficult to cut by the machine.
- Increased product weight: Excessive wall thickness of aluminum die castings will also lead to increased product weight, which will affect the cost of transportation, use, and maintenance of the product.
Due to the large thermal expansion coefficient of aluminum material, the too-thick wall thickness of aluminum die castings will lead to uneven thermal expansion, causing the product to deform, warp, or even crack.
Effect of the too-thin wall thickness of aluminum die casting
Aluminum dies castings with too thin walls can negatively affect their strength and durability. Wall thicknesses that are too thin can make parts warp, crack or warp easily, thus shortening the life of the part. In addition, the too-thin wall thickness will also increase the possibility of quality problems in the processing and production of aluminum die castings.
If the wall thickness is too thin, aluminum die castings will be more susceptible to external impact and extrusion, and thus more prone to deformation and cracking. In addition, the too-thin wall thickness will also affect the surface quality of aluminum die castings and increase inevitable defects. All of these factors can lead to parts needing to be replaced and repaired more frequently, increasing downtime and maintenance costs.
Therefore, when dealing with aluminum die castings, the wall thickness must be strictly controlled to ensure compliance with the design requirements and to reduce weight as much as possible while ensuring strength.
Wall Thickness Standards for Aluminum Die Castings
The wall thickness standard of aluminum die castings is generally based on factors such as design requirements, process conditions, and alloy properties. Generally, the minimum wall thickness of aluminum die castings should ensure its strength, rigidity, and sealing performance, and take into account factors such as thermal deformation and shrinkage during the casting process.
Specifically, the minimum wall thickness of aluminum die castings are generally required to be 1 mm, but the actual wall thickness needs to be considered comprehensively based on factors such as specific structures and materials. If the wall thickness is too thin, it may cause problems such as defects, deformation, cracks, and insufficiency in the casting; on the contrary, if the wall thickness is too thick, it may increase the cost, increase the weight and affect the manufacturing efficiency and other factors.
minimum wall thickness for aluminum casting
The minimum wall thickness of aluminum die castings should usually be kept at about 1.5mm. This is due to the high fluidity and solidification shrinkage of aluminum alloys, and a certain thin meat profile needs to be reserved during casting to ensure high-quality castings. At the same time, considering the material and structural requirements of the casting, sometimes the minimum wall thickness may also need to be adjusted according to the specific situation.
In short, the wall thickness standard of aluminum die castings should be comprehensively analyzed and judged according to the specific situation, and at the same time, it is necessary to comply with the casting process specifications and material performance requirements to obtain the best casting effect.