DIE CASTING
Taiyuan Simis Investment Casting Co., Ltd.,Taiyuan Simis Investment Casting Co is a leading die casting manufacturer in northern China, focusing on providing customers with integrated solutions of aluminum alloy die casting and zinc alloy die casting from mold development to mass production. With ISO 9001 and CE dual certification, we serve more than 300 enterprise customers worldwide.
Die Casting, an advanced metal forming process, propels molten metal into precision molds with extraordinary force and velocity. Distinguished by its formidable 200-400MPa pressure and blistering 16-80 m/s injection speeds, this technique achieves complete mold filling and solidification within a breathtaking 0.01-0.2 second window. Particularly transformative for mass-producing aluminum, zinc, and magnesium alloys, die casting delivers remarkable ±0.02mm dimensional precision and Ra0.8-6.3μm surface refinement, while slashing post-processing requirements by 60% compared to conventional casting methods.
20+
die casting experience
500,000
Pieces of monthly capacity
3-5
Days rapid sample delivery
8h
Get quotation and feasibility plan
Customer demand
3D drawing confirmation
Mold development
(7-15 days)
Sample testing
Batch production
Deliver customers
Hot-chamber die casting (commonly called gooseneck casting) specializes in producing detailed small to medium components through an integrated furnace system. This method features a submerged injection mechanism where molten metal remains heated within the furnace chamber. A hydraulic plunger drives the liquefied metal through a gooseneck conduit into precision molds.
This technique offers rapid cycle times due to constant metal availability in the heating reservoir. Its application is restricted to metals with lower melting temperatures, including zinc alloys, magnesium composites, and specific copper-based materials, ensuring optimal flow characteristics during the molding process.
This technique offers rapid cycle times due to constant metal availability in the heating reservoir. Its application is restricted to metals with lower melting temperatures, including zinc alloys, magnesium composites, and specific copper-based materials, ensuring optimal flow characteristics during the molding process.
Cold chamber die casting, with its separate injection system design, offers significant advantages in the manufacture of large workpieces and high-strength metal parts. The process introduces the molten metal liquid accurately into the injection chamber at room temperature (15-25℃) by manual pouring, and then the metal solution is pressed into the mold cavity at high speed by the high-pressure plunger mechanism. The injection system made of special steel effectively avoids premature solidification of the metal solution.
With a wide range of material adaptibility, the technology is compatible with alloys such as aluminum, brass and cast iron, ensuring precision forming quality of structural parts while significantly improving process stability by insulating liquid metal from continuous thermal exposure. However, it should be noted that its production cycle is 30-40% longer than that of the hot chamber method, the process volatility caused by the manual pouring link and the higher unit energy consumption caused by the intermittent production mode constitute the main constraints of this technology in practical application.
With a wide range of material adaptibility, the technology is compatible with alloys such as aluminum, brass and cast iron, ensuring precision forming quality of structural parts while significantly improving process stability by insulating liquid metal from continuous thermal exposure. However, it should be noted that its production cycle is 30-40% longer than that of the hot chamber method, the process volatility caused by the manual pouring link and the higher unit energy consumption caused by the intermittent production mode constitute the main constraints of this technology in practical application.
Vertical die casting machine can process a variety of metals (such as zinc, aluminum, copper, etc.), usually used for special shape or high precision parts. Its vertically oriented injection system ensures superior filling consistency and reduced porosity, making it ideal for components requiring complex geometries or thin-walled structures.
The gravity-assisted mold design enhances production efficiency while minimizing material waste, particularly suited for manufacturing automotive components, electrical connectors, and industrial hardware with strict tolerances. Advanced temperature control and automated ejection mechanisms further optimize cycle times, ensuring high repeatability across mass production batches.
High pressure die casting is a process in which a metal liquid is subjected to high pressure (up to 150MPa) by a die casting machine, so that the metal liquid fills the mold cavity at high speed and solidifies under pressure.
The core of the process is "high pressure and high speed", suitable for the production of thin wall, complex parts (such as automobile engine shell, electronic components).
Applicable materials: mainly used for non-ferrous metal alloys (such as aluminum alloy, zinc alloy, magnesium alloy), especially suitable for low melting point metals.
Advantages & Disadvantage
* Advantages: high production efficiency, good surface finish, high dimensional accuracy.
* Disadvantages: high mold cost, easy to produce porosity and shrinkage defects, casting can not be heat treatment.
The core of the process is "high pressure and high speed", suitable for the production of thin wall, complex parts (such as automobile engine shell, electronic components).
Applicable materials: mainly used for non-ferrous metal alloys (such as aluminum alloy, zinc alloy, magnesium alloy), especially suitable for low melting point metals.
Advantages & Disadvantage
* Advantages: high production efficiency, good surface finish, high dimensional accuracy.
* Disadvantages: high mold cost, easy to produce porosity and shrinkage defects, casting can not be heat treatment.
Low pressure casting uses compressed air (the pressure is usually 20~100kPa) to press the metal liquid from bottom to top into the mold, and solidify under the pressure. The filling speed is slow, but the metal liquid flows smoothly, suitable for large thin wall complex parts (such as hub, cylinder head).
Applicable materials: aluminum alloy is the main, but also can be used for magnesium alloy, copper alloy and other non-ferrous metals.
Advantages & Disadvantages
Advantages: high density of casting, few pores, can be heat treated, high material utilization (small riser).
Disadvantages: large equipment investment, production efficiency is lower than high pressure casting.
Applicable materials: aluminum alloy is the main, but also can be used for magnesium alloy, copper alloy and other non-ferrous metals.
Advantages & Disadvantages
Advantages: high density of casting, few pores, can be heat treated, high material utilization (small riser).
Disadvantages: large equipment investment, production efficiency is lower than high pressure casting.
The metal liquid relies on gravity to naturally fill the metal mold cavity, without external pressure, the process is simple and the mold life is long.
There are two forms:
Sand gravity casting: using sand mold, suitable for single piece or small batch production, the surface of the casting is rough.
Metal gravity casting: using heat-resistant alloy steel mold, the castings are strong and dimensionally stable, suitable for medium and large thick wall parts (such as machine base)
Applicable materials: aluminum alloy, copper alloy, cast iron and other black and non-ferrous metals are applicable.
Advantages & Disadvantages
* Advantages: low mold cost, can produce thick wall parts, fewer internal pores and high elongation of castings.
* Disadvantages: poor surface finish, low production efficiency, not suitable for thin wall complex parts.
There are two forms:
Sand gravity casting: using sand mold, suitable for single piece or small batch production, the surface of the casting is rough.
Metal gravity casting: using heat-resistant alloy steel mold, the castings are strong and dimensionally stable, suitable for medium and large thick wall parts (such as machine base)
Applicable materials: aluminum alloy, copper alloy, cast iron and other black and non-ferrous metals are applicable.
Advantages & Disadvantages
* Advantages: low mold cost, can produce thick wall parts, fewer internal pores and high elongation of castings.
* Disadvantages: poor surface finish, low production efficiency, not suitable for thin wall complex parts.
Manufactured from aluminum alloys like ADC12/A380 using cold chamber die casting, ideal for automotive components (engine brackets, transmission housings) and electronics (heat sinks).
The process ensures corrosion resistance with high surface finish (Ra 1.6-3.2μm) and dimensional accuracy (IT11-13).
Features include T5/T6 heat treatments, vacuum-assisted casting (<0.1% porosity), and efficient production cycles (45-120s) with automated systems.
Complies with ISO 9001/IATF 16949 through X-ray and CMM inspections, achieving >85% material utilization via integrated recycling.
The process ensures corrosion resistance with high surface finish (Ra 1.6-3.2μm) and dimensional accuracy (IT11-13).
Features include T5/T6 heat treatments, vacuum-assisted casting (<0.1% porosity), and efficient production cycles (45-120s) with automated systems.
Complies with ISO 9001/IATF 16949 through X-ray and CMM inspections, achieving >85% material utilization via integrated recycling.
Zinc die casting predominantly utilizes the hot chamber process, immersing the injection mechanism directly within molten zinc. Widely employed zinc alloys such as the Zamak series—including Zamak 3 and Zamak 5—blend zinc with aluminum, magnesium, and copper. These alloys boast exceptional fluidity, enabling the creation of intricate designs and remarkably thin walls (as slim as ~0.5 mm). Zamak 5, distinguished by its elevated aluminum content, delivers superior mechanical strength while maintaining precision-casting capabilities.
Advantages: High precision and smooth surface finishes reduce secondary machining; cost-effective due to low energy consumption and high-speed production; durable with strong mechanical properties and dimensional stability; recyclable materials support sustainability; adaptable to plating, painting, or corrosion-resistant coatings.
Disadvantages: Heavier than aluminum/magnesium due to zinc’s density; prone to corrosion without protective coatings; high initial tooling costs make small batches uneconomical.
Advantages: High precision and smooth surface finishes reduce secondary machining; cost-effective due to low energy consumption and high-speed production; durable with strong mechanical properties and dimensional stability; recyclable materials support sustainability; adaptable to plating, painting, or corrosion-resistant coatings.
Disadvantages: Heavier than aluminum/magnesium due to zinc’s density; prone to corrosion without protective coatings; high initial tooling costs make small batches uneconomical.
Copper die casting injects molten copper alloys (e.g., brass, bronze) into steel dies under high pressure. Due to copper’s high melting point (~1085°C), the cold chamber process is used, where metal is ladled into a separate chamber, making it slower and more energy-intensive than zinc die casting. Pure copper is rarely cast due to reactivity and challenges, while alloys like brass and bronze improve castability, strength, and corrosion resistance.
Advantages： include exceptional thermal/electrical conductivity, corrosion resistance (especially in marine settings), antimicrobial properties, and aesthetic appeal with gold-like finishes.
Disadvantages： high energy costs, accelerated tooling wear from heat/pressure, limited fluidity (requiring thicker walls), and higher material costs compared to zinc or aluminum pose challenges. Zinc die casting offers lower costs, easier processing, and greater design flexibility due to superior fluidity.
Advantages： include exceptional thermal/electrical conductivity, corrosion resistance (especially in marine settings), antimicrobial properties, and aesthetic appeal with gold-like finishes.
Disadvantages： high energy costs, accelerated tooling wear from heat/pressure, limited fluidity (requiring thicker walls), and higher material costs compared to zinc or aluminum pose challenges. Zinc die casting offers lower costs, easier processing, and greater design flexibility due to superior fluidity.
WHAT DO YOU WANT TO KNOWFAQ
We have made a general analysis of your questions
For further technical details of the die casting process or for customized solutions, please feel free to contact our Specialty Alloy Die Casting division. Our technical team can provide technical support for the whole process from mold development to post-processing.
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How to solve the blister defect of die casting?
We can reduce the porosity to less than 0.1% through vacuum die casting technology, and ensure quality with X-ray nondestructive testing.
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Do small orders accept？
Support 1-5000 trial production orders, provide DFM report to optimize the design scheme.
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How to compensate for delivery delay?
The contract stipulates the overdue compensation clause, and the regular order delivery rate is 99.6%.
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Does the service provide post-surface treatment?
Supports sandblasting (Sa2.5 level), anodic oxidation (coating thickness 10-25μm), conductive oxidation (salt spray test for 96 hours), and 12 other surface treatment processes to meet IP68 protection requirements.