Making airplane parts with die casting uses strong, light metals. Common metals include aluminum (like A380), magnesium (like AZ91D), and titanium. These metals are chosen because they are strong but don’t weigh much.  Hot, melted metal is pushed into a steel mold very fast. This makes complicated shapes and fewer parts to put together.  It’s cheaper to make lots of parts this way. The melted metal is pushed into the mold with very high pressure (usually between 10 and 210 MPa). 

Let’s break down the deeper information about aerospace die casting in parts. That includes its unique methods, materials, applications, benefits, etc.

Aerospace Industry Demand

The aerospace industry always needs those parts that are strong yet light. However, traditional methods face challenges and often fail to generate these kinds of outputs. These parts can resist fatigue and handle extreme temperatures and pressures.

Therefore, in the early 20th century, die-casting methods came into existence and grew. These processes are now widely popular. They can produce complex parts within seconds.

Examples include landing gear components, satellite parts, and engine mounts.

Die casting involves simple steps. The initial step is to melt the material in a furnace. Then die casters shift this metal toward machines and evenly inject it into the die cavity. High pressures are applied, and the die remains closed tightly until the parts become solid and ready for removal.

Benefits of Aerospace Die Casting

1.   Precision and Accuracy

The manufacturers produce precision aerospace parts. They make sure the part perfectly fits with accurate measurements. This part also includes tolerances of +/- 0.005 inches or better. For example, engines and turbines.

2.   Complex Geometries

Why do manufacturers take weeks to complete a mold? Because intricate shapes of parts are still challenging for every technique. Therefore, they make sure the mold contains the strength of the pressures and the precision and complexity of cooling.

That way, they obtain different shapes with internal cooling channels and undercuts during casting. These features make the part feasible toward better performance and minimize material usage. For instance, die-casting techniques can produce complex parts, achieving a complexity level of 8/10.

3.   Weight Reduction

You can make 15 to 25 % lighter aerospace parts with die casting. These parts contribute to reducing fuel usage by up to 10% and lower emissions in airplanes and spacecraft. In addition to this, this process minimizes emissions. It facilitates climate protection.

4.   Cost-Effectiveness

Die-casting processes require less labor and machining work. Hence, it saves production time by around 50% and money up to 30%. Faster production also reduces overall expenses while maintaining high quality.

5.   Material Waste Minimization

Essentially, this process contributes to more sustainable and eco-friendly environments. Because it uses less material and also minimizes its waste during casting. That can be around 70%.

 Aerospace Die Casting Materials

Aerospace industry applications rely on several material options. But in particular, the following are their preferred materials with special qualities.

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We all know aluminum is known for its common feature of being lightweight. It has a strength-to-weight ratio of 90,000 psi / 2.7 g/cm³. This material prevents rust in wet conditions for as much as 1000 hours.

Aluminum also transfers heat and resists damage in better ways. All these features of this metal are vital for aircraft parts. These are engines, bodies, satellites, etc.

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Magnesium alloys are light but offer strength in parts. Their strength-to-weight ratio is 200 MPa / 1.8 g/cm³.

Manufacturers can easily shape them into complex parts. It can decrease vibration better than aluminum.

Moreover, magnesium aerospace parts like engine mounts, satellite components, and missile parts stay strong. They can handle continuous stress and reduce shaking.

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These materials are strong (40,000 psi) and have a high strength-to-weight ratio. Their gravity is 7.0, and is less dense than copper. It can resist rust under moderate circumstances for up to 500 hours.

They easily flow into the die cavity and spread properly by filling every corner of the mold. This flexibility allows the manufacturers to make detailed parts with fine finishing.

They use zinc alloys to make parts because they offer durable and easy-to-shape facilities. For instance, small hardware, engine parts, and electronic systems.

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Copper contains specific strength, which is around 24.7 kN·m/kg. They transfer heat (300 W/m-K) effectively. It also defends against rust even under salty water conditions for up to 2000 hours. Additionally, copper is also a strong (60,000 ps) option for aerospace parts like heat exchangers, electrical parts, and rocket components.

Tooling Materials in Aerospace Die Casting

Steel Mold

Do you know steel molds are very common in die casting? Because they are stronger than the cast part and handle high heat. You can use steel mods to make parts like airplane wings and engine parts. Surprisingly, steel mold stays strong and lasts more than 100,000 uses without damage. They also do not lose their shape even in intense heat and pressure.

Aluminum Mold

You will find aluminum molds at cheaper rates and in lightweight. This kind of mold is usable for making small parts or prototypes. For example,  you can make testing samples like small screws, clips, or connectors. However, you must not rely on these soft metal mold types. Because they can not withstand higher temperatures.

Why does it matter?

Why does tooling material matter in aerospace die casting? The engineers select mold material based on the part being made. By doing this, they choose either steel mold or another tough one if the part is subject to a lot of stress or high heat. However, they choose the aluminum mold for smaller or less-stressed parts, saving money and time.

Mold Design Rules for Aerospace Components

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In diecasting machines, cooling channels are like pipes or holes. The manufacturers flow cold water or oil from these pathways inside the mold. That converts the molten particle into solid form and cools down the mold evenly.

Cooling channels save parts from shrinkage and uneven shapes. They keep the part accurate. For aluminum parts, maintain mold temperature between 180 and 220 °C.

Venting

Dies contain small gaps called vents. These gaps let air escape. Imagine if the vents are not there in mold, then bubbles that happen during casting can ruin the shape of parts. These bubbles also affect the part’s strength and cause cracks.

Vents are also important for thin parts. They maintain their actual shape, such as brackets, to keep them strong.

Ejection Systems

Manufacturers add pins and plates to ejection systems. These tools help them to push out the molded part from the die.

Pins and plates should push parts with even force. In this manner, they do not bend or break delicate parts.

For example, thin components like satellites need careful ejection. So that they stay in shape.

Melting Processes in Aerospace Die Casting

1.   Induction Melting

The manufacturer uses an alternating current (AC) for induction melting. This current generates a magnetic field. That causes the formation of the EMF (electromotive force). These forces melt the material evenly and quickly. Common frequencies of AC currents are:

• Medium frequency (MF) around 1-10 kHz
• High frequency (HF) around 10-100 kHz
• Very high frequency (VHF) around 100-500 kHz

However, the temperature depends on the material type. For example, aluminum is melted at 650–700 °C for parts like engine blocks. Also, the manufacturer ensures there are no impurities in the metal, and it is clean to use for casting.

2.   Crucible Melting

Crucible methods include various parameters, especially if they use heat to melt materials. First of all, the temperature ranges from 500 to 2000 °C, depending on the metal melting point. Likewise, the manufacturer maintains holding temperature between 1000 and 1800 °C.

They control the heat rate between 1 and 10 °C/min and let the metal soak for 30 minutes to several hours. Besides this, they manage heat flux at 1-10 kW/m. Fuel consumption for heating varies and depends on the furnace type.

However, if you use a gas-fired furnace, then it may use around 1-10 m³/h, and an oil-fired furnace uses 1-10 L/h. Manufacturers melt the metal at atmospheric pressure, around 1013 mbar.

But for vacuum die-casting, it may be around 10-1000 mbar. The crucible method is very simple. It works well for smaller parts. Such as switches and electronic connections.

Post-Processing Operations in Aerospace Die Casting

1.   Trimming

Trimming in aerospace die casting techniques is important to remove the left-over metal around the molded part. The manufacturers clean the edges with a cutting machine. These machines keep the edges and corners smooth and accurate. Because aerospace parts must have less than 0.1 mm of error in edges.

2.   Heat Treatment

Heat treatment during de-casting makes aerospace components stronger. The manufacturers first melt the metal parts, like aluminum, to 530 °C. They are then swiftly cooled and reheated to 160°C. This process is beneficial for making heavy-load parts. For instance, landing gear.

3.   Surface Finishing:

When you convert raw metal material to a specific product, it must need additional surface treatment to resist rust and wear. Therefore, manufacturers apply several coatings, like electroplating and titanium nitride coating.

For example, they add electroplated thinner layers 5–10 µm to stop corrosion in the zinc part. Similarly, anodized aluminum parts contain a layer 20–25 µm thick for protection. Zinc parts are electroplated with a thinner layer of 5–10 µm to stop corrosion.

Overview of Die Casting Techniques in Aerospace

Vacuum Die Casting:

Vacuum die casting for aerospace creates error-free parts. It removes air interruption during casting. Because the presence of air in mold causes bubbles. That leads to part damage.  So, this process protects the part from porosity and cracks.

Using this technique, you can get stronger and smoother parts. For instance, satellite housings must avoid stress and cracks.

Squeeze Die Casting:

Manufacturers use squeeze die casting to make denser parts. These parts are more durable and stronger. In this technique,  they press the metal when it cools with the punch or plunger part. This process removes air gaps.

Manufacturers pressurize the metal to compact it for solid ingots. For hollow shapes, they insert the core inside the mold cavity and apply pressure to fill the surrounding space.

Squeeze casting is useful for the production of heavy-duty parts like landing gear brackets. Because these brackets are subjected to holding a lot of weight without bending or breaking.

الخلاصة:

الفضاء الجوي صب القوالب is a manufacturing process. The manufacturers use it for the creation of tough-shaped aircraft parts. They inject molten metals like aluminum, zinc, or magnesium into dies to get near-net-shape products. Die-casting processes include vacuum or squeeze casting. Also, manufacturers choose the right material for mold to increase their performance.