Pressure Casting

High-pressure die casting of aluminum alloys
High-pressure die casting of zinc alloys

Casting of aluminum alloys
and zinc

Our foundry operations are based on a fleet of cold-chamber die casting machines for aluminum alloys, with clamping forces ranging from 180 to 700 tons, and hot-chamber die casting machines for zinc alloys, with clamping forces from 10 to 220 tons. Components with increased sealing requirements are cast using vacuum equipment, which enables the creation of reduced-pressure conditions inside the mold cavity.

In our casting processes, we use the following alloys:

DIN 226 (EN AC 46000)
DIN 231 (EN AC 47100)
DIN 230 (EN AC 44300)
DIN 239 (EN AC 43400)
ZL 5 (ZL0410)

We have a fully equipped laboratory for testing and evaluation of:

the chemical composition of alloys,
the internal structure of castings,
the density index of alloys and castings,
dimensional accuracy and surface quality of parts.

The laboratory staff are provided with equipment such as:

a spectrometer,
an X-ray machine
a density measurement device,
a digital microscope.
3D coordinate measuring machine.

Industries served

Currently, the company’s production profile consists of approximately 500 types of high-pressure castings which recipects are national and international companies operating in industries such as:

automotive

household items

furniture

electrical industry

construction industry

other industries

Quick contact

(+48) 34 314 24 26

Pon. – Pt. : 7:00 – 16:00

kontakt@zomn-press.com.pl

Do you have questions? We will be happy to answer

Do you have questions about molds, manufacturing or machining? Contact us – we will be happy to explain everything.

(+48) 34 314 24 26

Pon. – Pt. : 7:00 – 16:00

FAQ

Frequently asked
questions

What are the main advantages of die casting?

One of the main advantages of this technology consists of the ability to reproduce very complex shapes within the mould cavity while maintaining high dimensional accuracy and surface quality of the final casting. Die casting of aluminum and zinc alloys also enables the production of very large series in a relatively short time.

What are the biggest disadvantages of die casting?

The biggest disadvantage of die casting is the high initial cost, resulting from the very expensive machines and casting tooling. This, consequently, limits the suitability of using this technology for small production runs, making them unprofitable.

What are the differences between hot and cold chamber die casting machines?

The term hot chamber refers to the temperature of the injection system, which is submerged in molten metal inside the melting furnace. As the metal doesn’t have to be transferred into the injection mechanism, production efficiency can be higher. The hot chamber process is limited to metals with lower melting points or those that do not react with steel, such as zinc, lead, tin, and some magnesium alloys. The term cold chamber, on the other hand, refers to the fact that the injection system is not in direct contact with the molten metal. In this process, the metal is melted in an external furnace and then transferred into the injection mechanism when the machine is ready for the shot. Due to the fact the metal has to be moved into the system, the process is generally less efficient than the hot chamber method. Aluminium, copper, some magnesium alloys, and zinc alloys with high aluminium content are usually produced using the cold-chamber die casting process.

What dimensional accuracy can be reached in this process?

In the case of die casting aluminium and zinc alloys, a dimensional accuracy of +0.30 to –0.30 mm is attainable.

Do you have a defined minimum production quantity?

Yes, a minimum production quantity is defined for each project. It is determined by a number of factors, such as the number of cavities forming the casting in the mold.

Do you fulfill orders below the minimum production quantity?

Yes, we fulfill orders below the minimum production quantity, on the condition that each batch is subject to individual pricing.

What are your lead times for orders?

Lead times depend on a production schedule established in coordination with each customer, as well as their current needs, our available capacity, and other circumstances. Nonetheless, our goal is to deliver ordered production batches within the confirmed timeframe and as quickly as possible — which, so far, we have been consistently successful at.