What are die-casting machinery parts?

Die cast machinery parts refer to metal components formed through high-pressure casting technology, which are widely used as core structures or functional components in industrial equipment, automobiles, aerospace and other fields. Its core value lies in its high strength, complex geometric forming ability, and mass production efficiency.

1. Essence of Process
High pressure rapid solidification: Molten metal (aluminum/zinc/magnesium/copper alloy) is injected into a steel mold at high speed under a pressure of thousands of tons, and rapidly cooled to form.
Precision repeatability: the first mock examination multi cavity design can be used to mass produce parts with the same size, reducing post processing.

2. Typical application classification
Structural load-bearing components:
Equipment bracket, gearbox housing (such as gearbox housing)
Engine bracket, hydraulic valve block
Sports functional components:
Transmission gear (high hardness characteristics of zinc alloy)
Bearing seat, connecting rod head (requiring high dimensional stability)
Sealed containment components:
Gas/liquid pump housing (die cast dense leak proof)
Compressor cylinder head (pressure and temperature resistant)
Cooling system components:
Internal combustion engine cooling fan (lightweight aluminum alloy)
Motor end cover (thermal conductivity+structural integration)

3. Core advantages
Strength to weight ratio: Under the same load, die cast parts reduce weight by more than 50% compared to plastic parts and have fewer welding points than sheet metal parts.
Geometric degrees of freedom: capable of forming complex internal flow channels, thin-walled reinforcement ribs, and irregular surfaces (such as turbine blades).
Cost efficiency: Mass production costs are lower than forging/machining, especially for small parts such as connectors.

4. Material performance orientation
Aluminum alloy (ADC12/A380): universal type, balancing strength and cost (accounting for 70% of industrial parts).
Zinc alloy (ZA-8/27): high hardness, wear-resistant, suitable for moving parts such as gears and locks.
Magnesium alloy (AZ91D): Extreme lightweight requirements (aerospace fasteners).
Copper alloy (brass): conductive/heat-conducting components (such as electrical contact sockets).

5. Process limitations and countermeasures
Wall thickness limitation: Too thin (<1mm) can lead to insufficient filling, while too thick (>8mm) can result in porosity. Therefore, it is necessary to optimize the design of the reinforcement bars.
Internal defects: Shrinkage porosity may reduce fatigue strength → Important components require X-ray inspection or T6 heat treatment for strengthening.
Size shrinkage: Cooling deformation affects assembly accuracy → Reserved machining allowance or local CNC finishing.

6. Competitive differentiation from other processes
Compared to plastic injection molding, die-casting parts can withstand high temperatures/loads, but the mold is 3-5 times more expensive.
Compared to machining: Die casting is suitable for mass production of complex parts, but turning simple shaft parts is more economical.
Compared to powder metallurgy: Die casting has higher strength, but powder metallurgy can be used for oil containing self-lubricating bearings.