The primary alloy materials for die casting include tin, lead, zinc, aluminum, magnesium, copper, and others. Zinc and aluminum alloys are the most widely applied, followed by magnesium and copper alloys. Currently, zinc, aluminum, and magnesium alloys dominate applications in the electronics industry.

Die-Cast Zinc Alloys

Zinc alloys boast excellent fluidity in the molten state and feature a low melting point of only 365°C. They can undergo various post-processing treatments, such as electroplating, resulting in extensive applications. They were once widely used in the mobile phone industry but have been gradually replaced by aluminum alloys due to their high specific gravity and poor corrosion resistance. The bathroom and sanitary ware industry is now the largest consumer of zinc die castings. Common grades include Alloy No. 2, 3, 4, 5, and 7, with Alloy No. 3 being the most prevalent.

Die-Cast Aluminum Alloys

Aluminum alloys have a low density yet relatively high strength, which is close to or even exceeds that of high-quality steel. With good plasticity, they can be processed into various profiles and possess excellent electrical conductivity, thermal conductivity, and corrosion resistance. They are widely used in industry, with consumption second only to steel. The specific weight of aluminum alloys is approximately one-third that of iron, making them indispensable across all industries, especially in the lightweighting of aircraft, ships, automobiles, electronic instruments, and other products.

Commonly used alloys belong to the Al-Si-Cu system, including typical grades such as ADC12 (A383) and ADC10 (A380). Other systems include Al-Si, Al-Si-Mg, and Al-Mg alloys. So-called aluminum-titanium alloys are modified by adding titanium to the aforementioned base materials; the addition of titanium can significantly enhance the mechanical properties of finished products.

Die-Cast Magnesium Alloys

Magnesium alloys are based on magnesium with other alloying elements added. Their key characteristics include low density, high specific strength, high specific modulus of elasticity, excellent heat dissipation and shock absorption performance, higher impact load capacity than aluminum alloys, and good resistance to corrosion by organic compounds and alkalis. The specific gravity of magnesium is roughly two-thirds that of aluminum and one-fourth that of iron, so magnesium alloys are widely utilized in electronic devices (mobile phones, communication equipment), automotive parts, and medical devices.

Magnesium-aluminum alloys are the most commonly used, followed by magnesium-manganese alloys and magnesium-zinc-zirconium alloys. Typical commercial grades include AZ91D, AM60B, AM50A, AS41B, among others.

Die Casting Molds

Die casting molds must be fabricated from hot work tool steels. Common steel grades include H13, 2344, 8407, 8418, SKD61, DAC, FDAC, and others.

Mold structure: (core half, cavity half) mold base, mold insert, guide pillar, guide bushing, ejector pin, sleeve ejector, sprue spreader, sprue bushing, slide unit, angle pin, hydraulic core puller.

Mold processing equipment: milling machine, CNC machining center, wire-cut EDM (slow wire), mirror EDM, surface grinding machine, lathe, mold welding repair equipment.