Low Pressure Die Casting Foundry

Low pressure die casting is generally used to produce metal parts that are symmetrical in shape and design, for example, wheel rims and steering knuckles for automobiles may be cast using low pressure casting process. Aluminum is the most commonly chosen alloy.

LPDC is less suitable for very thin-walled parts where the required thickness is less than 3mm. It’s also relatively slower than those components produced in high-pressure processes. Machine size will also limit the size of castings.

What is Low Pressure Casting

In low pressure casting process, the low-pressure air is used to force molten metal from a sealed holding furnace up into a mold cavity, the pressure is applied constantly, sometimes in increasing increments, to fill the mold and hold the metal in place within the die until it solidifies.

Once the cast has solidified, the pressure is released and any residual liquid in the tube or cavity flows back into the holding furnace for recycling. When cooled, the cast is simply removed. it is considered a permanent mold casting process since the molds that make the castings are permanent and can be reused for many cycles.

Low pressure die-casting primarily uses alloys with low melting points and allows for the production of components up to around 150 kg. The advantages are very high strength and the ability to form complex geometries, whilst maximising material usage.

Why Choose SIPX

With over 10 years of experience, Sipx is well versed in this field. Yes, you are dealing with masters. You can trust us with your needs and expectations.

You will save 20-30% of the cost because of our excellent production capacity. Furthermore, we only insist on making high-quality casting products.

  • Rapid Prototyping
  • One-Stop Services Supplier, On-demand manufacturing
  • ISO16949 Certificated
  • Strict Quality Control System

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    The automotive industry has relied upon low-pressure die casting for decades to create strong, high-quality aluminum casts. However, due to its relatively slow casting process, its use was primarily limited to the luxury class of the automotive market, where lower quantities and higher costs are expected. Now, though, having successfully sought out ways to make this method more cost-effective (e.g. making the machines larger overall, but space-saving due to their vertical construction), the automotive industry has decreased the time of the casting cycle by 50%, making low-pressure casting a far more economical choice than it once was.

    Although low-pressure casting is an exceptional choice for automotive components such as engine blocks, wheels, and suspension parts, non-automotive industries such as electronics, machine-building, and pipe assemblies also benefit from its lower machining costs, high volume yield, and exceptional metallurgic quality. Cast aluminum’s superior electrical and thermal conductivity make it a very desirable choice for all of these industries.

    Advantages of Low Pressure Casting

    The process is less suitable for very thin-walled parts where the required thickness is less than 3mm. Low pressure die-casting is also relatively slower than those components produced in high-pressure processes. Machine size will also limit the size of castings.

    • This method allows precise control of the filling process.
    • Less oxide formation and reduced porosity, ensuring superior consistency from top to bottom.
    • Good formability because the filling of liquid metal under pressure can improve the fluidity of liquid metal.
    • Cost-effective, easy to realize mechanization and automation.

    Materials

    Low pressure die-casting primarily uses alloys with low melting points and allows for the production of components up to around 150 kg. The most common alloys that are die cast are shown below, along with brief descriptions of their properties.

    Material Tensile Strength (Mpa) Thermal Conductivity (W/mK) Features
    Aluminum A380 325 96 Best combination of mechanical, casting, and the thermal properties.
    Excellent fluidity, pressure tightness, and resistance to hot cracking.
    Widely used for engine brackets, hand tools, electronic equipment chassis, gearbox cases, and household furniture.
    Aluminum A360 317 113 Excellent pressure tightness and fluidity.
    High corrosion resistance.
    High strength in elevated temperatures.
    Aluminum 413 295 121 Good combination of casting, mechanical, and thermal properties.
    Excellent fluidity, pressure tightness, and resistance to hot cracking.
    Aluminum 383 310 96 Often used for highly intricate components.
    Good corrosion resistance, lightweight.
    Good combination of casting, mechanical, and dimension stability.
    Aluminum B390 317 134 High hardness and good wear resistance.
    Suitable for internal combustion engine pistons, cylinder bodies for compressors, and brakes.
    Aluminum A413 290 121 Excellent pressure tightness.
    Good choice for hydraulic cylinders.
    Suitable for die casting intricate components.

    Alternatives

    There are several alternatives to low-pressure casting. One such alternative is sand casting, which accounts for the vast majority of metal casting overall. By forming a mixture of sand, clay, and water around complex shapes, molds are created, filled with molten metal, and broken away once the cast has solidified. The high-heat properties of sand make this an excellent method of molding. Investment casting is another option. Investment casting is favored today by many industries for its accuracy and versatility. Another alternative to low-pressure casting is gravity casting (or permanent mold casting). A simple process of filling hollow forms with molten metal and allowing gravity to flow into every recess of the mold, gravity casting offers several advantages such as smooth surfaces, superb dimensional accuracy and faster production times. The gravity die casting process is also well suited for the automotive industry.