Die Casting

Why Choose Chi-Tai As Your Aluminum Die Casting and Zinc Casting Manufacturer?

• Chi-Tai is a aluminum and zinc die casting manufacturer that provides services ranging from design concepts to production and packaging. We have fulfilled orders for products in various industries in different countries, such as the United States, Europe, and Japan.
• Chi-Tai can resolve problems. Our customers value our ability to turn complex design specifications into completed products.
• Chi-Tai can handle all of the aspects regarding aluminum and zinc die casting, from mold design and testing to precision aluminum and zinc part manufacturing, post-processing tasks, including grinding, machining and coating, and the packaging.

The advantages of Chi-Tai die casting manufacturing functions are:

1 Quality Stability with Excellent Equipment

Chi-Tai also uses multiple forms of technology to ensure efficient completion of any die-casting project.

1. Using the Thurner minimum filling time (MFT) vacuum system leads to exhausting air inside mold cavities before injecting the alloy, and thus improving the integrity of the metal casting, as well as reducing mold wear. This process makes the part fill quickly by reducing back pressure and ensuring a high injection rate. Products produced by applying the MFT system have:
   • Better surface smoothness
   • Reduced gas porosity
   • Reduced leakage problems
2. Using a superior quality electronic furnace: temperature stability is the most important casting factor, ensuring the products’ quality stability during manufacturing.
3. Using a central melting furnace and automatic liquid distribution, while limiting exposure to dangerous environmental factors during the production process.

2 Quality Management in Die Casting Plant

1. On-site personnel conduct quality patrols every 2 hours during mass production to prevent unexpected situations and ensure that quality products are produced on time.
2. Using a superior quality electronic furnace: temperature stability is the most important casting factor, ensuring the products’ quality stability during manufacturing.
3. Using a central melting furnace and automatic liquid distribution, while limiting exposure to dangerous environmental factors during the production process.

3 Semi-Automated Circular Production

Automation improves production efficiency.

4 Die-Casting Equipment Overview (On-site Capacity and Partnered Facilities):

We manage a tightly coordinated supply chain and possess a total of 40 die-casting machines on-site, each equipped with the latest technology to meet a wide range of production needs. In cases of exceptionally high demand or specialized requirements, we have established partnerships with trusted local facilities, allowing us to seamlessly scale our production capacity.

Step 5: Die-casting machine

• Die casting machines perform the process of casting metal by pressing molten metal into a mold cavity under high pressure.
• Our factory has a range of die-casting machines, ranging from 150 to 420 tons, that can produce most types of castings.
• We work closely with our supply chain, and have 50 die-casting machines to ensure we have enough production capacity. Chi-Tai is able to produce castings with a locking force of up to 1200 tons.

Precision Aluminum and Zinc Die Casting Capabilities

• Chi-Tai has complete die-casting capabilities on site to meet customers' requirements for die-casting quality control. During the process of aluminum and zinc die-casting manufacturing, porosity (shrinkage or gas porosity) may naturally occur. Factors related to part dimensions, mold design, and manufacturing processes are important considerations for reducing porosity. Porosity can cause parts to fail to lock out various gasses or fluids under pressure, leading to product failures, and can also determine the viability(useful) of the part.

• Pressure injection is a fast and effective process that can reduce the inherent porosity problems that are sometimes found in die-casting parts. Injection is an essential part of the process in the vacuum chamber. First, the molten aluminum is injected into the mold cavity to fill the voids caused by shrinkage or gas porosity. Next, the molten aluminum solidifies into a solid, filling the voids and sealing off these leak paths. If the castings are properly treated, they are appropriately completed without defects, and the appearance or dimensions will not change.

Vacuum machine

• To minimize porosity, each die-casting machine is equipped with a vacuum machine. This function extracts air from any cavities in a mold, allowing the die-casting machine to inject molten aluminum into a vacuum space.
• By doing so, we can prevent porosity from entering the molten aluminum and causing sand or air holes during the die-casting process. The ultimate goal of this process is to reduce porosity in the die-casting sample.

Step 6: Removing the Scraps

• The die-casting mold contains a customized biscuit and a runner with an overflow well, which enables the molding of components within the mold.
• Once the die-casting molding process is finished by using a die-casting machine, the product is conveyed by a conveyor belt to a centralized workbench, where the scraps can be eliminated either manually or by using a stamping machine.

What is the process for managing a die-casting plant?

1. Quality Control Management during the die casting process

At the die casting plant, we have a team of quality assurance personnel who diligently monitor the quality of die casting samples. There are two operators on duty during both day and night shifts, and their responsibility is to inspect the critical dimensions of die casting samples, ensuring that the mass-produced castings in the manufacturing process are stable and meet our clients' requirements.

2. Production Process Traceability Within 24 Hours

To detect any defective products during production, each casting sample will be placed on a shelf every 2 hours. This enables us to continuously trace production history.

During these regular spot checks, our quality assurance personnel can identify any defects and review all of the mass-produced products. Should any defects be found among these samples, our quality assurance inspector can immediately halt production and address the issue before production can be resumed.

The following die-casting samples are stored on a shelf:

1. Standard samples: these are the samples that clients approve after the small-scale trial production of the first batch. If any defects occur during this first production batch, plant personnel can compare it with the standard sample.
2. The first sample: this is the first accepted sample produced from the batch that is made by using the master sample mold.
3. Temporary samples: these are the samples collected every two hours during the production process to trace defective products.
4. Final sample and sample storage: these are the final approved samples produced from the batch using the mold. They will serve as the standard for the approved sample for the next scheduled mass production, and will be stored in the sample storage space thereafter. Plant personnel use the final sample to ensure uniformity of sample conditions before it is used in the next scheduled production.

3. X-ray Inspection Machinery

Due to the manufacturing process of casting through high-pressure fluid injection, the occurrence of porosity is unavoidable. However, by utilizing X-ray machinery for inspection, we can detect and identify porosity issues that are not visible to the naked eye.

4. Chi-tai's On-Site Mold Factory

The on-site mold factory is responsible for performing maintenance work on molds, such as removing carbon within the factory to prevent dimensional defects during the next die-casting production.