Technology Comparison

Comparison of the high pressure die casting, gravity die casting and hot foring :

Those three techniques are complementary and better meet the needs of our customers. Indeed, the high pressure die casting allows, after liquefying the metal, to inject it under high pressure in a steel mold and so obtaining pieces that can be worked with thin thickness. By this method the machining and finishing operations of the parts are often limited. pièce comparaison des technologies
Similarly, in gravity die casting The liquid metal is cast by gravity into the mold. This means that the parts can not be so worked than in high pressure die casting and must have larger overall thicknesses. Some alloy not being able to be high pressure die casted, the gravity foundry has all its interest. pièce comparaison des technologies
On the other hand the hot forging Consists in heating the material to make it "soft" while remaining in the solid state and deforming it by a sudden impact in a steel tooling. The part is thus formed with a burr.
This burr is an overweight of peripheral material which will then be eliminated by a die cutting. This technique, due to the fact that the metal is not melted, does not destroy the original spinning of the spun material and thus produces pieces of high resistance, without premeability.

  • Comparaison des technologies 1
  • Comparaison des technologies 2
  • Comparaison des technologies 3

In a few cases, it's possible to associate those two techniques to, for exemple, couler des ébauches de forme très approchante et de matricer (frapper) ces ébauches pour les écrouir et ainsi augmenter les caractéristiques mécaniques de la pièce finale. (?)

 

Characteristic High pressure die casting Gravity foundry
Hot forging
Profitability 5 000 to 10 000 pieces 100 to 1 000 pieces 500 to 2 000 pieces
Cost of the tooling Important Medium Medium
Shape type Hard worked Moderately worked Moderately worked
pieces thickness Parts that can be fine up to 1 mm Parts that can be fine beyond 3mm Rather massive pieces
Sketch Empty Empty Sometimes necessary
Overmoulding insert Possible Possible Empty
Mechanical resistance Moderate Excellent after hardening Excellent
Structure of matter Can contain porosities Can contain porosities No porosities
Sealing Moderate Good Very good
Surface Condition Moderate / Good Moderate Moderate / Really good
Hardness Hard oxidized layer Hard oxidized layer Ability to recover in cold calibration
Polishing ability Moderate Moderate Good
Ability to be machined Moderate Moderate Good
Production Multi-cavity Multi-cavity Usually mono-cavity
Completion Limited Moderate Important
Matter type Aluminium, Brass, Bronze, Zamak Aluminium, Brass, Bronze, Cupro aluminium Aluminium, Brass, Bronze, Copper, CuCr, CuTe, Cupro, Titanium

 

Alloys High pressure die casting Aluminium Forging Aluminium Gravity foundry Aluminium High pressure die casting Brass Forging Brass Forging Copper High pressure die casting Zamak
Norm and alloys type EN AC-46000
AS9U3
EN 2017A
AU4G
EN AC-42200
AS7G06
EN 1982
60/40
EN 12165
CuZn39Pb2
EN 12165
CuA1
EN 10774
Zamak5
Density 2.75 2.79 2.67 8.4 8.4 8.9 6.7
Technology High pressure die casting Hot forging Gravity die casting foundry Foundry Hot forging Hot forging High pressure die casting
Caracteristic Lightness and resistance complex shapes Lightness and resistance Moderate complexity shapes and resistance Resistance Resistance and sealing Electric conduction Complex shape resistance
Average price per kg * 2 €/Kg 4 €/Kg 2.75 €/Kg 5.25 €/Kg 5 €/Kg 6 €/Kg 2.10 €/Kg
Average price per L * 7.25 €/L 13.50 €/L 10.50 €/L 52.50 €/L 46.75 €/L 56.50 €/L 19 €/L
Recycling capacity Excellent Really good Excellent Really good Really good Really good Moderate
Receiving State Lingot Stretch bar Lingot Lingot Stretch bar Stretch bar Lingot
Transformation temperature 700°C 500°C 700°C 1050°C 750°C 800°C 430°C
Alloys High pressure die casting Aluminium Hot foring Aluminium Gravity foundry die casting Aluminium High pressure die casting brass Hot forging brass Hot forging Copper High pressure die casting Zamak
Processability Good Moderate Good Good Good Moderate Really good
Minimum mechanical resistance 240 Mpa 390 Mpa 320 Mpa 350 Mpa 350 Mpa 200 Mpa 331 Mpa
Electric conduction
15% IACS 34% IACS 23% IACS - 27% IACS 100% IACS 26% IACS
Heat resistance
Good Good Good Good Good Moderate Weak
Superficial hardening
No No - No No Yes No
Ability to be machined
Good Good Good Good Good Moderate Good
Friction ability
Moderate Moderate - Good Good - -
riveting ability
Moderate Bad Moderate Moderate Moderate Really good Really good
Welding Stirring
Good Good - Good Good Good Good
Thermic treatment No Yes Yes No No No No
Longevity of tools Moderate Moderate Moderate Weak Moderate Moderate Very long

CuTe = Tellurium Copper // CuCr = Chromium copper

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