Raw Materials Preparation
Material Inspection: The raw materials of magnesium alloy should be examined for chemistry, purity, and the other physical characteristics for verification that they are up to the standards of production.
Die Production and Design
Design Considerations: The die must be designed with proper consideration of the shape, size, and accuracy requirements of the magnesium alloy die castings. The draft angles of the parts, the wall thickness, and the gate locations are maintained under careful consideration for effective molten alloy filling and solidification.
Manufacturing Process: The dies are produced with precision machine processes. The best quality of the tool steels are most frequently utilized for the materials of the dies for withstanding the pressure conditions and heat while the operation of the die-casting remains in progress.
Die - Casting Process
Melting: The magnesium alloy melts within specially constructed molten furnace under the cover of gas atmosphere of the protective type (the combination of N₂ and SF₆) for avoiding oxidation. The alloy should be of the correct fluidity by the proper control of the melting point.
Injection: The molten alloy of magnesium under pressure and at high velocity is injected into the die cavity. The rate of injection, the injection pressure, and the duration of injection are regulated with reference to the particular part design and the characteristics of the alloy.
Solidification: The molten alloy solidifies in the die cavity when it is injected. The cooling is carefully controlled so that internal stresses and shrinkage defects in the castings are not developed.
Post - Processing
Trimming: The excess material (flash) of the parts that are being die-cast are removed by the operation of trimming.
Heat Treatment: The heat treatment can be utilized for enhancing the mechanical characteristics of the magnesium alloy die cast parts including the tensile strength and hardness. Solution treatment and the treatment by aging are the most extensive heat treatment processes.
Surface Finishing: Surface treatment such as electroplating, paintwork, or anodizing can be done for the improvement of the appearance and anticorrosion characteristics of the parts.
Quality Control
Inspection Methods: The non-destructive inspection methods of X-ray inspection, ultrasonic inspection, and magnetic particle inspection are being utilized for the detection of the internal defaults of the die castings. Dimensional inspection with the precision measuring equipment is done for the verification of the parts for the purpose of confirming that the parts are within the design requirements.
Quality Assurance System: A strong quality assurance system is put in place that verifies that the manufacturing processes are strictly controlled and that the final products are of the quality necessary for precision use.
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