HPDC vs LPDC Die Casting

High-Pressure Die Casting (HPDC)

Process Overview: High-pressure die casting involves injecting molten metal into a pressure chamber where it rapidly fills the mold cavity and solidifies under high pressure. The flow speed during filling can reach 30-80 mm/s, and the entire cavity filling process happens in a very short time.

Advantages:

· Produces castings with good surface finish and stable dimensions.

· Allows for direct molding of thin-walled structures.

· High work efficiency and smooth surface finish that can be directly painted.

Disadvantages:

· High operating and investment costs.

· Difficulty in casting thicker parts.

· Porosity issues, making parts unsuitable for heat treatment.

Features and Applications:

· High-speed, high-pressure, and precise metal casting.

· Suitable for thin-walled castings with complex shapes, offering high dimensional accuracy and surface quality.

· Primarily used in mass production of non-ferrous metals like aluminum, magnesium, zinc, and copper, particularly in automotive, electronics, and aerospace industries.

· New technologies and equipment are improving casting quality, though issues like porosity still exist.

Low-Pressure Die Casting (LPDC)

Process Overview: In low-pressure die casting, the liquid alloy fills the mold cavity from the bottom up under lower pressure and solidifies under pressure. Unlike HPDC, LPDC allows for heat treatment due to different pressure levels and metal flow directions.

Advantages:

· Fewer defects like porosity and slag inclusion due to stable filling.

· Dense structure with high mechanical properties.

· Strong filling ability, producing castings with clear contours and smooth surfaces.

Disadvantages:

· Lower productivity compared to HPDC.

· Although HPDC produces a better surface quality, LPDC is better suited for castings with higher air-tightness requirements.

Features and Applications:

· LPDC is ideal for castings with high air-tightness requirements and thicker walls, as it allows for heat treatment and improved toughness.

· It uses molds made from sand, metal, or graphite, resulting in purer and denser castings with smooth surfaces.

· LPDC offers high production efficiency and is conducive to mechanization and automation.

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